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504G3

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 504G3 Series

Страница 1: ...OPERATION MANUAL COMPACT TRACTOR 504G3 WWW KNEGT INTERNATIONAL COM...

Страница 2: ...504G3 SERIES TRACTOR OPERATION MANUAL Please Read and Save This Manual KNEGT QUALITY TRACTOR EUROPE 2018 09...

Страница 3: ...ic PTO clutch two 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 appear...

Страница 4: ...our safety Read these safety rules attentively and strictly follow suggested precautions to avoid any potential danger and ensure your health and personal safety In order to meet users needs continuou...

Страница 5: ...unning in of hydraulic hitch system 28 3 4 Running in of hydraulic steering system 28 3 5 Running in of PTO 28 3 6 Running in of the Tractor 29 3 7 Maintenance after running in 30 Chapter 4 Operating...

Страница 6: ...raulic steering system 84 7 8 PTO 85 7 9 Hydraulic Hitch System 86 7 10 Electrical system 87 7 11 Heating system 88 Chapter 8 Appendix 89 Appendix 1 Standards and Regulations 89 Appendix 2 Tightening...

Страница 7: ...unction 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 ca...

Страница 8: ...specified 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 y...

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: ...ads 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 independe...

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: ...ign 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 assistant weight support or ax...

Страница 18: ...the engine in safe place 4 When needing get out of the CAB in case of the danger but the door of CAB can t be opend or the door is not suitable for escaping then open the emergency escape window behi...

Страница 19: ...Rated Speed rmp DF504G3 4WD 36 2400 independent Hang YES 2 2 Identifying your machine 2 2 1 Machine Identification Plate Your machine has an identification plate mounted on the front right hand side o...

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: ...all Height To ROPS 2502 To CAB 2451 Tyre Front 8 3 20 Rear 12 4 28 Wheel track mm Front 1300 Rear 1300 Wheel base mm 1880 Minimum ground clearance mm 357 Steering radius m without braking 3 7 Construc...

Страница 22: ...axle Rear axle 2135 841 1294 2258 881 1377 Technically permissible laden masses Kg Total mass Front axle Rear axle 2415 1009 1406 2538 1049 1489 Permissible laden masses by tyre type Allowed load spe...

Страница 23: ...nder L type direct injection Number of cylinders 4 Bore and stroke mm 95 115 Total displacement L 3 26 Compression 18 5 Cylinder sleeve style Dry Rated power speed kW rpm 36 2400 Rate fuel consumption...

Страница 24: ...evel gears Transfer case Vertical column gear with shift 2 3 4 Travelling and steering system Model DF504G3 Front wheel drive axle Bevel gear drive axle Front axle alignin g Front wheel toe in mm 4 8...

Страница 25: ...ole of up lift mm 28 7 Diameter of the hole of down lift mm 22 5 Tractor Drawbar Diameter of Pin mm 30 Groud clearance mm 302 397 Clevis type Diameter of Pin mm 40 Groud clearance mm 441 PTO shaft Typ...

Страница 26: ...ignal lamp Position lamp 4W white Direction indicator lamp 21W yellow Rear combination lamp Stop lamp 21W red Position lamp 5W red Direction indicator lamp 21W amber Work lamp H3 12V 55W White 2 3 7 C...

Страница 27: ...U No 1322 2014 ANNEX Requirements applying to the driver s exposure to noise level DF504G3 Max permissible value in Directive SOUND LEVEL EXTERNAL 82 8 dB A 89 dB A SOUND LEVELS INTERNAL 85 6 dB A 86...

Страница 28: ...504G3 SERIES TRACTOR OPERATION MANUAL 26 awS awB 2 Class Light driver 0 996 Heavy driver 1 070...

Страница 29: ...water 5 Check air pressure of the the tires 6 Check proportion and height of battery electrolyte 7 Put Shuttle shift lever range shift lever and gear shift lever on netural position Disengage the 4WD...

Страница 30: ...k trouble immediately 3 4 Running in of hydraulic steering system 1 Park the tractor on the flat road 2 Start the engine let the engine work in low speed mid speed and high speed Turn the steering whe...

Страница 31: ...ged gradually from low to high Also you must steer and turn the tractor often while performing the above procedures The total time needed to running in the tractor with a load is 50 hours The running...

Страница 32: ...Whether the electrical equipment and all kinds of instrument is working properly In process of running in if abnormal phenomena are found the cause should be found and the running in can be continued...

Страница 33: ...o transmission system lifter and front axle as per specified after reinstall well 3 Drain out coolant and after clean cooling system by water 4 Clean diesel filter and air cleaner 5 Check front toe in...

Страница 34: ...RACTOR OPERATION MANUAL 32 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 35: ...5 Foot Throttle 16 Brake Pedal 17 Hand Throttle 18 Steering Wheel 4 1 2 Instrument Panel and Switch Fig 4 2 Instrument panel and switch 1 Instrument Panel 2 Grouped Switch 3 Switch Plate 1 Ignition Sw...

Страница 36: ...th 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 pressure Indicator 4 End Outline Posi...

Страница 37: ...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 38: ...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 39: ...d warning signal switch It is only used to switch ON the hazard warning signal Hazard warning signal should light when tractor should be repaired on road or running in night 1 is ON position 2 PTO Swi...

Страница 40: ...at right put the switch on 1 position to engage the heater the warm wind will be blown out form the air outlet in CAB And 0 position to turn off the heater 3 Use and adjustment of system for heating a...

Страница 41: ...n CAB Fig 4 9 1 Mode Switch 2 Power Switch 3 Radio seletion Next teack 4 Mute the sound 5 Preset station 2 INT 6 Preset station 3 RPT 7 Preset station 5 10 8 USB SLOT 9 SD MMC CARD PORT 10 Sount Files...

Страница 42: ...when driving the tractor at night 4 2 1 Getting on and leaving the tractor Tractor With Rops Getting on or leaving the tractor must only be made where steps A and handrails B are provided Always face...

Страница 43: ...adjusted seat will reduce operator fatigue Position the seat so that you can comfortably reach the machine controls For driving the machine adjust the seat so that you can depress the pedals fully wi...

Страница 44: ...chieved 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 that it is ov...

Страница 45: ...check 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...

Страница 46: ...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 47: ...t 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 Knegt dealer 3 Coolant Temperature Gauge T...

Страница 48: ...e obtained Select the proper gear The proper gear should be selected in order to let the engine work within 80 of the maximum power When rototilling place range shift lever in L or H Gear 1st 2st or 3...

Страница 49: ...turn To stop a tractor interlock brake pedals together with locking bar depress brake pedals Put gear shift in Netural position and shuttle shift in Netural position then pull the hand brake lever up...

Страница 50: ...ch pedal then slowly release the clutch pedal and push the 4WD Lever down to engage 4WD in time So tractor is in 4WD mode 2 When stop or shift the gear depress clutch pedal firstly pull the 4WD lever...

Страница 51: ...ageable parts of the tractor tires should be paid attention on their maintenance to extend their life Inflate the tires according to the regulations if the pressure is too low or too high is not permi...

Страница 52: ...p the shuttle and main gear shift levers in neutral 2 If the tractor stopped on a slope the engine must be shut down At the same time shift the shuttle and main speed into gear upgrade with the shuttl...

Страница 53: ...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 54: ...Use draft control lever to control the depth changes in a range so keep the draft load constant automatically This method is often applied when soil condition is almost the same See figure 4 21 a Move...

Страница 55: ...a lower gear 3 Float Control On uneven ground we need the implement float with the ground contour See figure 4 21 c Push position control lever all the way forward and draft control knob all the way...

Страница 56: ...ever The rate of drop knob fig 4 22 can be used to control the drop speed of implement and set the implement at desired position Choose the appropriate drop speed according to the weight of the implem...

Страница 57: ...nds and coupler receptacles are clean and dry 3 Coupler receive cylinder retract hose 4 Coupler receive cylinder extend hose 5 To connect each hose push hose tip firmly into coupler receptacle Pull li...

Страница 58: ...h pins on both sides and retains with locking pins When it is difficult to slip draft links over implement to hitch pins operate as following step 1 Push down Plate NO 1 in fig 4 24 2 Pull back adjust...

Страница 59: ...by loosening the jam nut fig4 25 on sway chain strainer and turning the sway chain strainer to increase or decrease the length of chain Tighten the jam nut again when adjusted 1 When plough is attach...

Страница 60: ...clutch when choosing the independent working PTO and when the users choose non independent working PTO the tractor don t have hydraulic clutch When the tractor need the power take off with an implemen...

Страница 61: ...Ballast The tractor traction consisting of tractors power and operation condition of the soil or road has been set so the main factors affecting the traction force play is the tractor quality and the...

Страница 62: ...the electrical schematic diagram 4 4 1 Generator and voltage regulator The generator is the main power supply of the tractor which is used to supply power to the electrical equipment and charge to the...

Страница 63: ...Please do not open the battery shell When battery shell burst by accident please don t dispose it at will because of sulfuric acid in the electrolyte of the battery is toxic it is easy to burn the sk...

Страница 64: ...nt load of electric equipment see fig 4 WARNING 1 If there is a fault in the electrical components check whether the fuse in the corresponding position of the line is burn out If it has been broken yo...

Страница 65: ...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 66: ...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 67: ...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 68: ...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 69: ...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 70: ...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 71: ...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 72: ...ake the lever and the bearing connect and rotating together As a result the clutch can t work efficiently any more So it should be check and adjust regularly As Fig 6 1 shows when assembling the clutc...

Страница 73: ...e path be in the stated range then tighten the adjusting nut 3 make the hole of the pull rod head part right at the proper place at last mount the shaft washer and the split pin 6 3 Adjustment of the...

Страница 74: ...e and right one doesn t exceed 400mm If it fails to reach the request adjust again 6 3 2 Adjustment of parking braking system Before regulating bring down the split pin and shaft then screw the nut 5...

Страница 75: ...d or the assemblage needs to be repaired The adjusting needs to be done after the bearings have been fastened 1 Check the clearance between the teeth Make sure the clearance of the pinion and crown ge...

Страница 76: ...ut without the correct clearance or on the other way it should be better to get the proper meshing zone with the clearance not less than 0 16mm 6 5 Adjustment of the Front Axle 4WD To inssure the reli...

Страница 77: ...it effect the gears to work normally or the bearings and the bevel gears need to be replaced or the assemblage needs to be repaired The adjusting needs to be done after the bearings have been fastene...

Страница 78: ...nt when it has the proper meshing zone but without the correct clearance or on the other way it should be better to get the proper meshing zone with the clearance not less than 0 2mm 6 5 3 Adjustment...

Страница 79: ...SERIES TRACTOR OPERATION MANUAL 77 Fig 6 5 1 Final reduction driven gear 2 Final reduction drive gear 3 Adjusting shim 4 Drive pinion 5 Driven pinion 6 Adjusting shim 7 Upper bearing cover 8 Steering...

Страница 80: ...Measure the front and rear distances between two steering wheels at the same height of the front wheels shaft through the center of steering wheels Adjust the assistant tie rod till the front distanc...

Страница 81: ...ol Check the lift height of the rockshaft after a period of time It should be adjusted if it is not sufficient Open the plug on the top of the housing use a screwdriver and turn clockwise slightly The...

Страница 82: ...aft control lever until the lift arms tend to lift Now the position of the draft control lever should be 5 to 10 degrees to the back end If it s bigger the 10 degrees tighten the adjust nut of draft l...

Страница 83: ...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 84: ...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 85: ...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 86: ...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 87: ...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 88: ...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 89: ...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 90: ...volume is insufficient Replace bearing Adjust Clean the oil and grind by 0 model non metal sand paper Fasten joint Grind by 0 model non metal sand paper Recharge 8 Starter motor continue rotate when...

Страница 91: ...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 92: ...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 93: ...504G3 SERIES TRACTOR OPERATION MANUAL 91 Appendix 3 Scheme of the electric system...

Страница 94: ...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 95: ...coupling non automatic trailer coupling 504G3 35B 001 clevis type according to directive 2009 144 EEC Annex as amended by 2013 8 EU tractor coupling and was found comply in all respects Type approval...

Страница 96: ...504G3 SERIES TRACTOR OPERATION MANUAL 94 2 2 ASSEMBLY See drawing no 504G3 35B 001 Use only bolts M16 8 8 Tightening torque 225 Nm CAUTION Secure all pins with cotter...

Страница 97: ...504G3 SERIES TRACTOR OPERATION MANUAL 95...

Страница 98: ...iler coupling 504G3 53 001 tractor drawbar according to directive 2009 144 EEC Annex as amended by 2013 8 EU tractor coupling and was found comply in all respects Type approval number CE e11 XXXX 1 3...

Страница 99: ...504G3 SERIES TRACTOR OPERATION MANUAL 97 2 2 ASSEMBLY See drawing no 504G3 53 001 Use only bolts M16 8 8 Tightening torque 225 Nm CAUTION Secure all pins with cotter...

Страница 100: ...504G3 SERIES TRACTOR OPERATION MANUAL 98...

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Страница 109: ...be attached 24 Front driven axle 4WD 84 Gearbox 83 Generator and voltage regulator 60 Getting on and leaving the tractor 40 Heating system 89 Hoist tractor 51 Hydraulic Hitch System 87 Hydraulic lift...

Страница 110: ...ctor Controls 32 Tractor Drawbar Or Clevis type Certification Plate 18 Tractor Maintenance 9 Tractor maintenance during storage 70 Tractor specification 19 Transmission 21 Travelling and steering syst...

Страница 111: ...18EC Version NO 00 00 00 First Print September 2018 Knegt Quality Tractors Europe Add Habraken 1207 5507TB Veldhoven Netherlands Tel 31 40 2558416 E mail info knegt international com Http www knegt in...

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