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404G2

SERIES TRACTOR OPERATION MANUAL

Chapter

Troubleshooting

Abration, deformation and improper servicing contribute to a technical change of the

components. Then it will cause troubles. At this time, the tractor must be checked and

get rid of them. If failed to do this, the conditions may be worse, even result in an

accident.

This chapter stress on the troubleshooting of chassis and electrical system. Details about

the engine troubleshooting will be showed in the operator’s manual of engine.

7.1 Clutch

Troubles & possible causes

Fixing methods

(1) Clutch slip

①

The clutch disk or clutch plate is stained
with oil.

②

Abrasion to clutch disk is uneven or the
abrasion is serious.

③

The free path is not enough or no free
path.

④

The driven disk is deformed.

①

Wash them clean with gasoline,
and eliminate the oil leakage

②

Replace the clutch disk

③

Readjust in accordance with the
requirement

④

Replace the driven disk

(2) Clutch cannot be separated completely

①

The pedal’s free path is too large, and the
working path is too small.

②

The driven disk warps too much.

③

The release finger of diaphragm spring are
not at the same plane

①

Adjust the pedal free travel as
specified

②

Rectify or replace with a new
one

③

Replace

(3) The tractor is shivering at starting

①

The friction disk and the driven disk are
stained with oil

②

The friction disk broke up

③

The driven disk warps

①

Clean friction disk and driven
disk

②

Replace

③

Replace

(4) There is vibration and noise in the cluch

①

Releasing bearing is lacking of oil or
broken

②

The spline of driven disk or the cluch has
been weared out

①

Oiling or replacing

②

Replacing

Содержание 404G2 Series

Страница 1: ...OPERATION MANUAL 404G2 WWW KNEGT INTERNATIONAL COM...

Страница 2: ...404G2 SERIES TRACTOR OPERATION MANUAL Please Read and Save This Manual KNEGT QUALITY TRACTORS EUROPE 2018 09...

Страница 3: ...speed PTO and so on All of these have improved the performance of the tractor greatly These tractors have the advantages of economic fuel consumption easy operation harmonious appearance compact cons...

Страница 4: ...ead these safety rules attentively and strictly follow suggested precautions to avoid any potential danger and safeguard your health and personal safety In order to meet users needs continuously this...

Страница 5: ...6 3 2 Running in the engine without load 26 3 3 Running in of hydraulic hitch system 27 3 4 Running in of hydraulic steering system 27 3 5 Running in of PTO 27 3 6 Running in of the Tractor 28 3 7 Mai...

Страница 6: ...iven axle 4WD 77 7 6 Walking system 78 7 7 Hydraulic steering system 78 7 8 PTO 79 7 9 Hydraulic Hitch System 80 7 10 Electrical system 81 Chapter 8 Appendix 83 Appendix 1 Standards and Regulations 83...

Страница 7: ...function and safety and affect service life of machine Lightning and high voltage cable can kill you Do not use the machine if there is lightning in your area or under high voltage cable Handle fuel c...

Страница 8: ...nspecified attachments can overload the machine causing possible damage and machine instability which could result in injury to yourself or others The use of non approved attachments could invalidate...

Страница 9: ...get on or off a moving tractor 6 Keep all children and nonessential personnel off tractors and all equipment 7 Always press the brake pedal gently 8 Reduce speed when turning applying individual brak...

Страница 10: ...loads with or without brakes that are too heavy for the tractors or are towed too fast can cause loss of control 3 For your personal safety trailers should not be towed unless equipped with an indepen...

Страница 11: ...and leaving the tractor 1 Before dismounting disengage PTO move transmission control lever to neutral stop engine lower implements or attachments to ground and securely engage the park brake In additi...

Страница 12: ...fuel might expand and escape In such case promptly wipe off any fuel that has escaped 7 Tractor fuel may be dangerous Never refuel while engine is running is still hot or you are near an open flame o...

Страница 13: ...tire assembly Use a safety cage if available Check wheels for low pressure cuts bubbles damaged rims or missing lug bolts and nuts 10 Improperly disposing of waste can threaten the environment and ec...

Страница 14: ...therwise you may be damaged On the right side of the radiator near the muffler 3 Keep away from radiator There may be hot fluids or steam Above the radiator 4 If you want to operate Please Read the op...

Страница 15: ...m 10 Power take off actuator and or rotational speed selector position 1000rpm 11 Only ride on the operator s seat Or it may cause serious accident on the right fender 12 Lifting mechanism control rai...

Страница 16: ...Panel 18 Checking and adjusting the fluid level Near the oil filler 19 Do not use the differential lock at high speed or on the road Beside the differential pedal on the outside surface of the squab p...

Страница 17: ...ine hood 27 Mandatory sign of front drive On the Seat plate 28 Mandatory sign of support point On the frame or rear axle housing or axle shaft housing 29 Mandatory sign of lifting point On the assista...

Страница 18: ...roper gear then go up the slope with smooth 3 If the brake system fails control the steering wheel slow down the tractor or shift to lower gear and running the tractor in neutral then shut down the en...

Страница 19: ...Speed rmp DF404G2 4WD 29 4 2400 independent Hang ROPS 2 2 Identifying your machine 2 2 1 Machine Identification Plate Your machine has an identification plate mounted on the front right hand side of...

Страница 20: ...ludes the engine model and serial number ROPS Certification Plate Your machine is built to the ROPS standard and has an identification identification label is shown below Label fitted to the ROPS or c...

Страница 21: ...Width 1575 1675 Overall Height To wheel 1590 To ROPS 2510 Tyre Front 7 5 16 Rear 12 4 24 Wheel track mm Front 1150 Rear 1260 1360 Wheel base mm 1900 Minimum ground clearance mm 366 Steering radius m...

Страница 22: ...yre type Allowed load speed Front axle 1300 30km h Rear axle 2830 30km h Ballast masses total weight material number of components Position Quantity Unit weight Total weight Front 6 20kg 120kg Rear 4...

Страница 23: ...4 5 Dry weight kg 250 External dimension mm Length 729 Width 516 Height 697 2 3 3 Transmission Tractor model 404G2 Clucth Linkage type double acting clutch Transmission 4 1 2 planar 3 shaft for main t...

Страница 24: ...essure Kpa 100 200 Tyre Option Front 280 70R16 Air pressure Kpa 200 300 Rear 360 70R24 Air pressure Kpa 100 200 Steering system Full Hydraulic steering gear Brake Dry disk type 2 3 5 Equipment Tractor...

Страница 25: ...ctangular spline Direction of rotation Clockwise face forward 2 3 6 Electricity and instrument panel Tractor model 404G2 Electric circut 12V single phase negative ground Battery 6 QW 80L Starter QDJ15...

Страница 26: ...ents to be attached 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 till...

Страница 27: ...to the driving seat 4 4 1 The arithmetic mean of the rms values of the weighted seat vibration acceleration awS 1 25m sec 2 Class Light driver 0 60 Heavy driver 1 15 4 4 2 Ratio of the arithmetic mea...

Страница 28: ...pressure of the the tires 6 Check proportion and height of battery electrolyte 7 Put Shuttle shift lever PTO shift lever range shift lever and gear shift lever on netural position Disengage the 4WD Li...

Страница 29: ...gh speed Turn the steering wheel left and right steady in proper order to do ten times pivot steering Check whether the steering is flexible and portable Check whether the steering system has oil leak...

Страница 30: ...is only allowed in fields or dirt roads Only low gears can be used to running in while the front drive axle is joining Disengage the front drive axle before the other gears running in Attention must b...

Страница 31: ...front axle when it is still warm meanwhile refill reasonable light diesel or kerosene If the engine does not start use slow speed drag tractor forward or backward about 3 minutes or lift the front and...

Страница 32: ...RACTOR OPERATION MANUAL 30 Chapter 4 Operating tractor 4 1 Instrument and Controls To prevent from accident it is necessary that you are familiar with instrument and controls 4 1 1 Tractor Controls Fi...

Страница 33: ...age lifting control 14 Parking brake control15 Gear shift lever 16 Differential locking pedal 17 Foot throttle pedal 18 Brake pedal 19 Hand throttle 4 1 2 Instrument Panel and Switch Fig 4 2 Instrumen...

Страница 34: ...operation in full hours and tenth White mark shows the rotational speed of engine Blue mark shows the rotational speed of PTO Fig 4 4 Instrument Panel 1 Fuel Gauge 2 Dipped Beam Indicator 3 Low pressu...

Страница 35: ...ght You should add fuel to fuel tank Charge Indicator Charge indicator lights when key is turned to START position and goes out after engine starts If charge indicator stays lit for longer than 5 sec...

Страница 36: ...preheat Indicator When ignition switch is on Preheat position thi indicates is working Headlight Indicator and Tail Lamp Indicator Headlight Indicator should glow when Headlight switch is switched to...

Страница 37: ...ch plate 1 Hazard warning signal Switch 2 Rear Work Lamp Switch 1 Hazard warning signal switch It is only used to switch ON the hazard warning signal Hazard warning signal should light when tractor sh...

Страница 38: ...peration The operator s seat can be adjusted for your comfort A correctly adjusted seat will reduce operator fatigue Position the seat so that you can comfortably reach the machine controls For drivin...

Страница 39: ...view is achieved Seat Belt 1 Fasten the Seat Belt a Sit correctly in the seat b Push the male fitting A into the buckle B until it latches into position Make sure the seat belt is not twisted and tha...

Страница 40: ...eck the oil level Oil level should be between upper and lower marks on the dipstick If low add oil 3 Drain water and sediment from fuel filter Before Starting the Engine CAUTION Prevent asphyxiation E...

Страница 41: ...wait until starter and engine stop turning before trying again Check all indicators are off after engine starts IMPORTANT DO NOT operate starter more than 15 seconds at a time If engine does not star...

Страница 42: ...stays lit for longer than 5 seconds under normal operating conditions stop engine and check for cause If loose or broken fan belt is not the cause see your Dongfeng dealer 3 Coolant Temperature Gauge...

Страница 43: ...e and work type The proper selection of gear can achieve maximum productivity and economical efficiency and can prolong the service life of the tractor The tractor should not be often overload The tra...

Страница 44: ...lock valve should be shut and PTO lever should be in the neutral position ATTENTION It is necessary to check whether the brake function work normally before the tractor departure It is not allowed to...

Страница 45: ...erential lock when one wheel is spinning and the other is completely stopped Use of the 4WD See fig 4 1 No 6 When driving on icy wet or gravel surface reduce speed and be sure tractor is properly ball...

Страница 46: ...the valve CAUTION 1 When the tractor travels at a high speed don t make an emergency turn with single brake 2 If the steering angle of the front wheels is too big and there is a noise in the valve you...

Страница 47: ...e the tractor on a slop please pull up the hand brake lever fully 6 Drain off the cooling water in winter CAUTION 1 The operator can not leave with the engine on And it s necessary to keep the shuttle...

Страница 48: ...isting slings is confirmed hoist slowly and move the tractor Put it to an appropriate position The carrying capacity of Crane must bigger than tractor technically permissible laden masses 4 2 9 Jack t...

Страница 49: ...linkage pin control handle will be back to the neutral position the farm implement will stop falling So you can make the farm implement down to the depth of the need for agricultural operations by fix...

Страница 50: ...aulic output system These series tractors are equipped with two sets of standard hydraulic output circuit the option of a set of hydraulic output circuits or simple hydraulic output circuit It is loca...

Страница 51: ...are connected together thus realizing the quick connection of the pipeline Make sure that hose ends and coupler receptacles are clean and dry 4 After using the hydraulic output valve place the multipl...

Страница 52: ...tivation Connecting farm implements Retreat tractor makes the connecting point close to the farm implemnts and controls the lifting handle so that the left and right lower pull rod can be connected to...

Страница 53: ...he lift rod and the length of the upper pull rod should be adjusted so that the furrow ploughing is consistent 3 When the tractor is equipped with farm implement the left and right limit chains limit...

Страница 54: ...ossed the ridge you should prevent the farm implement from bumping into the field or violently swing so as not to damage the tractor parts 4 3 4 Use Mechanical coupling There are two type mechanical c...

Страница 55: ...t after confirmation Using a power output shaft farm implements hoisting height should be determined by the angle between the power output shaft with implement the angle no more than 20 is advisable W...

Страница 56: ...is grounded the single line and double color system All kinds of electrical equipment adopt different wire diameters and different colored wires which are connected according to certain rules and requ...

Страница 57: ...ven damage the start motor 3 If three consecutive fails to start the tractor the condition of electromagnetic switch battery technology the battery connection wire connection situation as well as engi...

Страница 58: ...n time A battery that hasn t been recharged for long periods of time will be recharged at least once a month to prevent the plate vulcanisation 5 If the tractor is parked in the open air for a long ti...

Страница 59: ...fuse back in place 2 If the installed fuses are defined but the fuse is often burned which indicating that there may be a line faults should be checked and excluded It is not allowed to use multiple u...

Страница 60: ...ve axle hydraulic system and steering system All atmospheric temperature N100 D transmission drive hydraulic dual purpose oil GB443 84 Grease fittings All atmospheric temperature No 2 and No 3 calcic...

Страница 61: ...ne Check the liquid level of engine sump refill them if they are insufficient and make sure the level will be between the middle notch and the topper notch on the dipstick Never exceed the topper notc...

Страница 62: ...arts when they are loose check all the electrical connectors and wires examine and repair them if they are deviant 5 2 3 100h maintenance 1 Engine Change the oil in the sump clean the filter strainer...

Страница 63: ...dule will help your tractor work normally 2 The service interval is determined according to the condition of working and your experience 3 Remember that in any case it is better to check too much than...

Страница 64: ...d clearance of your machine The ramp should be long enough that the angles between the truck or trailer do not cause the machine components to catch when moving from ramp to truck or trailer If loadin...

Страница 65: ...on the painted metal parts store the tractor under cover and in dry and well ventilated places 3 Brush anti rust paint on the unpainted metal parts 4 Ensure that all controls are in neutral or off po...

Страница 66: ...t will discharge when not be used 5 4 3 Preparation after Storage 1 Remove the waterproof canvas clean the tractor 2 According to the request to fill with coolant diesel oil and lubricant 3 Check the...

Страница 67: ...abrading the clearance between the release lever s head and the release bearing become small and small even make the lever and the bearing connect and rotating together As a result the clutch can t wo...

Страница 68: ...ion of mark a to insure the pedal free path to be in the stated range tighten the adjusting nut 1 and 5 then adjust the Clutch pedal hold down bolt3 to make sure the clearance between release bearing...

Страница 69: ...d on the dry flat and then try to brake urgently After that check the tire print lengths Make sure the difference between left one and right one doesn t exceed 400mm If it fails to reach the request a...

Страница 70: ...on 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...

Страница 71: ...he gears or the bearings are abraded 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 shou...

Страница 72: ...fig 6 6 The two bearings 6 and 8 on the Bevel drive pinion should be pre stressed The adjustment of Bevel drive pinion is realized by altering the Adjusting shims on the left and right When adding or...

Страница 73: ...the clearance is large enough it should be adjusted When adjusting bring down the back seat put a lead piece between the teeth of pinion and crown gears The lead piece will be pushed to transform Then...

Страница 74: ...another is piece 6 9 They have been adjusted in the factory generally there is no need to adjust them by the users unless replacing the bearings and gears or do some repairs The two couples have the...

Страница 75: ...the steering wheel to the mid position to make the wheels straight Then loosen the left right helical nut 3 and 5 rotate assistant tie rod 4 Measure the front and rear distances between two steering...

Страница 76: ...4 Chaging the spoke s assembling position to the wheel rim the rear wheel track can be 1260mm 1360mm Wheel track of 1260mm would be the normal when assembling in the factory Users can adjust the wheel...

Страница 77: ...path is not enough or no free path The driven disk is deformed Wash them clean with gasoline and eliminate the oil leakage Replace the clutch disk Readjust in accordance with the requirement Replace t...

Страница 78: ...Remedy as per clutch troubles Replace or repair 3 The gear disconnects itself Poking fork positioning slot is worn seriously Interlock pin spring pressure isn t enough Spline of teeth seat are worn Ad...

Страница 79: ...ely and resulting in heat Grip brake still under operational The brake pedals free pathes is too small Loosen the grip brake Adjust 7 5 Front driven axle 4WD Troubles possible causes Fixing methods 1...

Страница 80: ...st improperly The front wheel rim deformed seriously Adjust to the request Replace Adjust Correct 2 The front tires are worn quickly The front wheel toe in adjust improperly The pressure of front tire...

Страница 81: ...other Steering oil case piston is damaged Replace poke pin Replace interlink shaft Reinstall Replace 4 The steering wheel can t return back The steering shaft isn t concentric with the rotor The steer...

Страница 82: ...en position Gear pump does not work a Oil level in the lifter is too low b Filter net blocked seriously Check and clean valve a Replenish oil to specified level b Clean or replace net 2 Lift up if lig...

Страница 83: ...ulfuration Check the generator or regulator Check and repair 2 The temperature of the accumulator is too high Current is too large Check and adjust 3 The generator does not generate power Rotor coil b...

Страница 84: ...unwell The main touch point of electromagnetic switch burnt out and have poor contact Battery volume is insufficient Replace bearing Adjust Clean the oil and grind by 0 model non metal sand paper Fast...

Страница 85: ...ental and propulsion unit performance requirements of agricultural and forestry vehicles 6 EU 2015 208 supplementing Regulation EU No 167 2013 of the European Parliament and of the Council with regard...

Страница 86: ...ission housing and gearbox housing M12 73 89 Grade 8 8 4 Connecting bolt for differential housing M10 41 51 Grade 8 8 5 Connecting bolt for spiral bevel gear and differential housing M10 1 46 56 Grade...

Страница 87: ...404G2 SERIES TRACTOR OPERATION MANUAL 85 Appendix 3 Scheme of the electric system...

Страница 88: ...Fuse box 1 8 504G3 47 015 Windshield 2 9 Rearview mirror 10 804 6 58 025 Oil filter 1 Appendix 5 List of Attached Tools No Code Name Qty Remarks 1 GB3390 1 89 Socket head S 13 1 2 Socket head S 16 1...

Страница 89: ...Jiangsu Province P R China 1 2 TYPE Tractor clevis mechanical coupling non automatic trailer coupling CODE DF300 6 35B 001 according to directive 2009 144 EC all IV appendix 1 fig 2 Type approval numb...

Страница 90: ...404G2 SERIES TRACTOR OPERATION MANUAL 88 2 2 ASSEMBLY See drawing no 300 6 35B 001 Use only bolts M16 8 8 Tightening torque 225 Nm CAUTION Secure all pins with cotter...

Страница 91: ...404G2 SERIES TRACTOR OPERATION MANUAL 89...

Страница 92: ...ina 1 2 TYPE Tractor drawbar mechanical coupling non automatic trailer coupling CODE DF300 53A 001 according to directive 2009 144 EC all IV appendix 1 fig 3 Type approval number CE e50 XXXX 1 3 TECHN...

Страница 93: ...404G2 SERIES TRACTOR OPERATION MANUAL 91 2 2 ASSEMBLY See drawing no 300 53A 001 Use only bolts M16 8 8 Tightening torque 225 Nm CAUTION Secure all pins with cotter...

Страница 94: ...404G2 SERIES TRACTOR OPERATION MANUAL 92...

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Страница 96: ...94...

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Страница 100: ...98...

Страница 101: ...99...

Страница 102: ...3 Attached tool kit of the tractor 1 List of tool box will be delivered additionally 4 Tractor operation manual 1 5 Tractor illustrated parts catalogue 1 6 Certificate of quality 1 Encasement member...

Страница 103: ...ractor 45 Driving the Tractor 41 Electrical system 81 Electricity and instrument panel 23 E MARK certificate 93 Engine 21 Engine Identification Plate Location 18 Equipment 22 Farm implement with wheel...

Страница 104: ...ain Bolts and Nuts 84 Towing loads 8 Tractor characteristic 17 Tractor Controls 30 Tractor Drawbar Or Clevis type Certification Plate 18 Tractor Maintenance 9 Tractor maintenance during storage 64 Tra...

Страница 105: ...NO 404G2 E 2018EC Version NO 00 00 00 F irst Print September 2018 KNEGT BV HABRAKEN 1207 5507TB VELDHOVEN NETHERLANDS 31 40 2558416 INFO KNEGT INTERNATIONAL COM WWW KNEGT INTERNATIONAL COM...

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