Table of Contents
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CONTENTS Service Manual 304G2
Safety
Precautions
......
Chapter I
Work safely Always and safety Rules .....................................
Chapter II
Technical Specifications of the Tractor ....................................
Chapter III
Running-in of the Tractor......................................................
Chapter IV
Operating The Tractor ...........................................................
Chapter V
Adjustments Of The Tractor.....................................................
Chapter VI
Lubrication And Maintenance Of The Tractor..............................
Chapter VII
Troubles and Trouble-shooting .............................................
Appendix 1
Moving Locus Diagram of Lifting Linkages.................................
Appendix 2
Moving Locus Diagram of Lifting Linkages.................................
Appendix 3
Diagram Of Electrical System Principle ....................................
Appendix 4
List
Seal...... .................
Appendix 5
List Of Bearings............................................. .....................
Appendix 6
Tightening Torque Table of Main Bolts and Nuts.......................... 63
Appendix 7
Optional Accessories ............................................................
Appendix 8
List of Attached Tools................................................ .........
Appendix 9
Packing
List
PRE-DELIVERY SERVICE........................................................................... 66
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of
Rubber
.........
................................................ ...... ...
... ..
Oil-seal
and
1
1
14
18
23
25
31
43
47
57
58
59
O-ring
60
62
63
64
65
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Summary of Contents for Dong Feng DF254G2-6
- Page 1 CONTENTS Service Manual 304G2 Safety …………………………..…………… Precautions …… Chapter I Work safely Always and safety Rules ……………….……………… Chapter II Technical Specifications of the Tractor ……………...……………… Chapter III Running-in of the Tractor……………………………………………… Chapter IV Operating the Tractor ………………………………..………………… Chapter V Adjustments of the Tractor…………………………..………………… Chapter VI Lubrication and Maintenance of the Tractor………...………………...
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Page 2: Precautions
Safety Precautions ★ ★ ★ ★ Recognize Safety Information This is a safety—alert symbol．When you 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 A signal word—DANGER，WARNING，or CAUTION—is used with the safety．alert symbol．DANGER identifies the most serious hazards．... - Page 3 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，...
- Page 4 HAND BRAKE before dismounting． Leaving transmission in gear with engine stopped will NOT prevent the tractor from moving． Be sure everyone 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，...
- Page 5 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，...
- Page 6 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 an 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...
- Page 7 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 ．...
- Page 8 ★ ★ ★ ★ 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 night．Follow local regulations for Equipment lighting and marking．Keep lighting and...
- Page 9 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...
- Page 10 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．...
- Page 11 Wear an approved respirator． ·lf 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． ★...
- Page 12 ★ ★ ★ ★ ervice Tires Safely Explosive separation of a tire and rim parts can cause serious injury or death． Do 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...
- Page 13 Chapter Ⅰ Ⅰ Ⅰ 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 his tractor has been designed and manufactured specifically and solely for agricultural use.
- Page 14 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-authorized and arbitrary modification made on the tractor will relieve the manufacturer of all responsibilities for any damage or injury deriving from such modification.
- Page 15 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. ■...
- Page 16 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. ■...
- Page 17 Tractor fuel may be dangerous. Never refuel while engine is running, or still hot, or near an open flame or when smoking. Chapter Ⅱ Ⅱ Ⅱ Ⅱ Technical Specifications of the Tractor Parameters of the tractor Tractor Model DF254G2-6 DF304G2-6 DF354G2-6 DF404G2-6 Length...
- Page 18 Rear wheel (Optional) In paddy field 4200 4950 5160 4970 Rated traction force (N) In dry field 6300 6940 7230 7856 Theoretic speed (km/hr) Gear Ⅰ 1.48 1.35 1.41 1.40 Gear Ⅱ 2.23 2.03 2.14 2.12 Gear Ⅲ 3.58 3.26 3.43 3.40 Gear Ⅳ...
- Page 19 2.2 Main technical specifications of the engine Tractor Model 254G2-6/304G2-6 354G2-6/404G2-6 Engine Model Vertical, Water cooling, Vertical, Water cooling, Type Four-stroke Four-stroke Number of cylinders Cylinder bore（mm） Piston stroke (mm) Piston displacement (L) 1.813 2.543 Compression ratio Cylinder sleeve type Rated power (kW ) 18.4 22.4...
- Page 20 Traveling and Steering System Tractor Model DF254G2-6/304G2-6 DF354G2-6/404G2-6 Bevel gear drive axle Front wheel drive axle Front wheel toe-in (mm) 5～10 Front Outward camber 3.5° axle King pin caster 0° aligning King pin inclination 7.5° Steering gear Full hydraulic steering gear...
- Page 21 Max. lifting weight at the point of 610 mm 4960 N 6650N beyond the mounting point ≤3 s Lifting time Pin hole diameter of upper- mounting point 19.5 mm Pin hole diameter of bottom- mounting point 22.5 mm Hitch pin diameter 30 mm Traction device...
- Page 22 Front combination light Position light White color The switch controls headlamps, rear working lights, marker lamps and flashers. Filling capacity Tractor Model DF254G2-6/304G2-6 DF354G2-6/404G2-6 Fuel tank 28 L (diesel) 28 L (diesel) Cooling system Engine sump Gearbox and rear axle...
- Page 23 failures. Running-in of engine without load 3.1.1 Please read carefully the engine operation manual before starting the engine. 3.1.2 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.
- Page 24 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.
- Page 25 Chapter Ⅳ Ⅳ Ⅳ 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.
- Page 26 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.
- Page 27 4.2.2 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.
- Page 28 a. Lifting & lowering the farm implements(seeFig. 3) Shift the control handle forward, then the attached implement will lowered down. Fix the depth stop block (1) at such a suitable position Fig. 3 Hydraulic lift that the pin (2) will just 1.
- Page 29 correctly. The upper link is for adjusting the fore-and-aft leveling of plow stock and the penetrability of the plowshare. Right & 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.
- Page 30 Chapter Ⅴ Ⅴ Ⅴ Ⅴ Adjustments of the tractor Adjustment of the engine Please refer to the engine operation manual for its adjustment. Adjustment of the clutch...
- Page 31 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.
- Page 32 16.Release bearing assembly 17. Release lever 18. Nut M10×1 19. Ruturn spring 20. Adjusting bolt 21. Flywheel rear Adjustment of the 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.
- Page 33 Points for attention: a. Make sure that front and rear wheels are symmetrical about the tractor centerline after adjustment is made. b. Rear wheels can be exchanged for adjusting wheel tracks (for rear wheel only). c. Make sure that the direction of lugs are determined by facing in the direction of forward travel.
- Page 34 Fig.7 Diagram of front wheel drive axle 1.Shims 2. Bolt M10×25 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.
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Page 35: Appendix
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-D04/04 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 The structure of the full hydraulic steering gear is shown in Fig. - Page 36 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 µ. The hydraulic oil should be renewed periodically.
- Page 37 Fig. 10 Adjustment of disc brake 1. Pull rod 2. Nut M16 3.Push rod 4. Nut M16Nut M12 5. Nut M12 6. Pull rod 7.Hand brake assemble 8. Nut M12 9. Self-aligning cushion 10. Pin 10x70 11. Brake assemble 12. Brake housing 13.
- Page 38 (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).
- Page 39 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;...
- Page 40 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.
- Page 41 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 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:...
- Page 42 Chapter VI Lubrication and Maintenance of the Tractor 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℃ ﹟ No.0 Light diesel 8℃～4℃...
- Page 43 Bottom of the oil tank Bottom of front wheel drive housing (four wheeled drive only) Bottom of transfer case housing Maintenance of the tractor 6.2.1 Every-shift maintenance A. Engine a. Make sure that the engine lube oil is enough and keep the oil level between the middle notch and upper notch on the dipstick.
- Page 44 Check opening pressure and atomization of injector, wash it clean and make adjustment if necessary. b. 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. 6.2.6 Maintenance after every 1000 working hours A.
- Page 45 bear 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 Chapter Ⅶ Ⅶ Ⅶ Ⅶ Troubles and Trouble-Shooting Engine Diesel engine fails to start 7.1.1 a. Breakdowns of fuel system Possible causes Fixing methods a. No fuel in fuel tank Add fuel b. Air in fuel system Bleed air, find out the reason and fix it up c.
- Page 47 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. No lube oil on the rocker shaft Possible causes Fixing methods a.
- Page 48 c. Blue smoke Possible causes Fixing methods a. The 3 ring is fitted upside down Refit it, with the ring face marked “上(up)” upward b. Wearing of piston rings and valve Replace them with new ones guides c. Too much high the lube oil level 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...
- Page 49 7.1.6 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 Check and make adjustment and fuel distribution among cylinders is considerable b. Air being in fuel pipes Bleed air c.
- Page 50 7.1.9 Rising of lube oil level Possible causes Fixing methods a. Water leakage from cylinder head gasket Check and replace it b. Water leakage from cylinder head or Repair with epoxy resin or replace with bowl-shaped plug hole in engine block a new plug 7.1.10 Engine running-away Possible causes...
- Page 51 e. Ends of the three release levers not Adjust and make the release lever ends in the in the same plane same plane 2. Clutch disengaged incompletely, resulting in difficult gear shifting or gear shifting with sound and tractor shaking while being driven away from rest.
- Page 52 a. Gearbox bearings or needle Check and replace worn out bearings or rollers excessively worn needle rollers with new ones damaged b. Abnormal meshing of main drive Examine gear meshing zone print and gears backlash, adjust them as per stipulations c.
- Page 53 7.2.5 Full hydraulic steering gears Troubles & possible causes Fixing methods 1. Steering operation is heavy a. Insufficient oil delivery of Check the hydraulic pump and fix up the hydraulic pump troubles if any b. Air bulbs in the hydraulic system Bleed air in the system, check the suction pipe and fix up the leakage if any c.
- Page 54 Electrical system 7.3.1 Battery Trouble & possible causes Fixing methods 1. Electric power always insufficient a. Generator or regulator failure Check wire connection and remove trouble b. Poor wire connection Check wire connection and remove trouble 2. Battery overheat Too high the charging electric Check and adjust regulator current 3.
- Page 55 Troubles & possible causes Fixing methods 1. Starter not working a. Connecting wire broken or poor Weld or replace with new connecting wire, clean contact of wire connection and the oil stain on contacts and tighten all the nuts switch contacts on connecting points b.
- Page 56 The lift members’ parameters and motion parameters (mm) Seq. The lower link Item points Length of lower link End span of lower link Height of farm implement’s column (recommended ) Length adjusting range of lifting rod 380～508 Connecting position of lifting rod’s lower end with lower link The ground clearance under the hitch point (while the lower link is at its lowest position)
- Page 57 The lift members’ parameters and motion parameters (mm) Seq. Item The lower link points Length of lower link End span of lower link Height of farm implement’s column (recommended ) 470 ～625 Length adjusting range of lifting rod Connecting position of lifting rod’s lower end with lower link The ground clearance under the hitch point (while the lower link is at its lowest position) The ground clearance under the hitch point (while the length of...
- Page 58 Appendix 4. List of Rubber Oil-seal and O-ring seal...
- Page 59 Standard Designation and specifications Quantity Location codes No. GB13871-92 Cased rubber oil seal FB 40×62×8 PTO shaft HG4-692-67 4 in Front wheel drive- Cased rubber oil seal W 50×72×7 axle HG4-692-67 4 in Front wheel drive Cased rubber oil seal PD 50×72×12 axle HG4-692-67 Final drive...
- Page 60 1 Front wheel drive GB 3452.1-92 axle O-ring seal 73×3.55 1 Gearbox GB 3452.1-92 O-ring seal 56×2.65 Front wheel drive axle Front wheel drive axle GB 3452.1-92 O-ring seal 69×3.55 Hydraulic lift GB 3452.1-92 Front wheel drive axle O-ring seal 23.6×2.65 1 in front wheel drive axle GB 3452.1-92...
- Page 61 Appendix 5. List of Bearings Standard code Designation and Quanti Location specifications Releasing bearing Clutch (release bearing assembly) 65TNK20 GB/T276-1994 Antifriction bearing 6106 Gearbox 4 in gearbox GB/T276-1994 Antifriction bearing 6208 2 in front wheel drive axle 1 in PTO shaft GB/T276-1994 Antifriction bearing 6207 2 in front wheel drive axle...
- Page 62 Appendix 6. Tightening Torque Table of Main Bolts and Nuts Seq. Tightening Location/Designation Specifications Intensity grade torque (N. m) Cylinder head / studs & nuts 118～137 Connecting rod / bolts M10×1 56～69 Main bearing / studs 115～125 Flywheel / bolts 98～118 Differential gear / bolts 40～50...
- Page 63 Appendix 8. List of Attached Tools Standard Code Designation and specifications Quantity Remarks GB3390.1-89 Socket head S=13 GB3390.1-89 Socket head S=16 GB3390.1-89 Socket head S=18 GB3390.1-89 Socket head S=24 GB3390.2-89 Square drive S=12.5 GB3390.2-89 Tommy bar L=300 Square drive with extension bar GB3390.2-89 S = 12.5 ×...
- Page 64 Appendix 9. Packing List Designation and specifications Quantity Remarks To be disposed as per DF Brand tractor order Spare parts & tool kit of the engine Attached tool kit of the tractor Operation manual of the tractor Illustrated parts catalogue of the tractor Certificate of quality 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...
- Page 65 for owner...
- Page 66 for dealer...
- Page 67 for manufacturer...
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