Jinma 200 Series Tractor Users Manual

Jinma 200 series Tractor Users Manual MCE 2004.01 JINMA 200 Series DOCUMENTATION Edited by: Steve Bradshaw Malacat Enterprises Cobble Hill, B.C. Version 0.2 Page 1 of 52

Jinma 200 series Tractor Users Manual MCE 2004.01 Table of Contents INTRODUCTION......................................................................................................................................7 Sources of data .................................................................................................................................7 PARTS.............................................................................................................................................. 7 Yancheng Tractor Factory..........................................................................................................................8 THE RULES.............................................................................................................................................. 9 Preventing Farm Machine Hazards .......................................................................................................... 11 AEX-593-91................................................................................................................................... 11 Shear and Cutting Points................................................................................................................ 11 Pinch Points ................................................................................................................................... 12 Wrap Points ................................................................................................................................... 12 Crush Points ...................................................................................................................................12 Free-Wheeling Parts....................................................................................................................... 13 Springs............................................................................................................................................ 13 Burn Points..................................................................................................................................... 13 Hydraulic Systems.......................................................................................................................... 13 MATERIAL SAFETY DATA SHEETS................................................................................................. 15 DISPOSAL OF POL WASTE........................................................................................................ 16 ENVIROMENTIAL LAW............................................................................................................. 16 Controls and Instruments......................................................................................................................... 17 Instruments (Standard)....................................................................................................................17 Amp meter:..................................................................................................................................... 17 Water Temperature Gauge: .............................................................................................................17 Oil Pressure Gauge......................................................................................................................... 17 Tachometer..................................................................................................................................... 17 Turning Signal Switch.................................................................................................................... 17 Work Light Switch......................................................................................................................... 17 Horn Button.................................................................................................................................... 17 Headlight Switch............................................................................................................................ 17 Starting Switch............................................................................................................................... 18 Instruments (Optional)............................................................................................................................. 18 Amp meter...................................................................................................................................... 18 Water Temperature Gauge.............................................................................................................. 18 Tachometer/Hour Meter: ................................................................................................................ 18 Oil Pressure Gauge......................................................................................................................... 18 Fuel Gauge...................................................................................................................................... 18 OPERATING CONTROLS..................................................................................................................... 19 Engine Shutoff Handle................................................................................................................... 19 Compression Release...................................................................................................................... 19 Hand Throttle.................................................................................................................................. 19 Clutch Pedal.................................................................................................................................... 19 4WD Selector..................................................................................................................................19 Version 0.2 Page 2 of 52

Jinma 200 series Tractor Users Manual MCE 2004.01 Transmission Gear Selector ............................................................................................................ 19 Hi-Lo Range Gear Shifting Lever.................................................................................................. 20 Left and Right Brake Pedals........................................................................................................... 20 Foot Throttle Pedal......................................................................................................................... 20 Parking Brake Lock Pawl............................................................................................................... 20 Creeper Shifting Lever................................................................................................................... 20 Hydraulic Control Lever................................................................................................................. 20 Differential Lock Lever.................................................................................................................. 20 Hydraulic Speed Regulator............................................................................................................. 20 Control and Operation of the Tractor ....................................................................................................... 21 Starting Engine............................................................................................................................... 21 Warm weather over 32 Degrees F..............................................................................................21 Cold weather below 32 Degrees F ............................................................................................ 21 Operating the Tractor...................................................................................................................... 21 Driving the Tractor......................................................................................................................... 22 Proper speed should be selected for best productivity. ..................................................................22 Stopping the Tractor....................................................................................................................... 22 Tractor Operation Safety................................................................................................................ 22 Control and Operation of the Working Devices .......................................................................................23 Control and Operation of PTO............................................................................................................ 23 Control and Operation of Hydraulic Hitch System............................................................................. 24 Position Control.............................................................................................................................. 24 Floating Control..............................................................................................................................24 Control of the Lowering Speed of the Implement .......................................................................... 24 Operation of Hitch System.................................................................................................................. 24 Adjusting of Longitudinal Level.................................................................................................... 24 Adjusting of Lateral Level.............................................................................................................. 25 Use of the Electrical Equipment .............................................................................................................. 26 Battery.............................................................................................................................................26 The Starter...................................................................................................................................... 26 Maintenance Schedule for the Tractor ..................................................................................................... 27 Daily Maintenance.......................................................................................................................... 27 50 Hour Maintenance (Every 50 Hours).........................................................................................27 250 Hour Maintenance (Every 250 Hours).....................................................................................27 500 Hour Maintenance (Every 500 Hours).....................................................................................27 1000 Hour Maintenance (Every 1000 Hours).................................................................................28 Maintenance for Long Term Storage.............................................................................................. 28 Tractor Adjustments................................................................................................................................. 29 Adjustment of clutch.......................................................................................................................29 Adjustment of brake....................................................................................................................... 30 Adjustment of disc brake................................................................................................................ 31 Free state adjustment of disc brake ........................................................................................... 31 Travel adjustment of brake pedal ............................................................................................... 31 Troubleshooting guide for Diesel Engines...............................................................................................32 SERVICE ADVISORIES........................................................................................................................ 34 Version 0.2 Page 3 of 52

Jinma 200 series Tractor Users Manual MCE 2004.01 50 hour, Head Re-torque.................................................................................................................34 18-28 HP Jinma Tractor Hydraulic Fluid Intake Filter ................................................................. 36 Backhoe Hydraulic Fluid Intake Filter .......................................................................................... 38 Injector Pump Oil .......................................................................................................................... 40 Oil Drains .......................................................................................................................................41 Ignition Switch Retrofit ................................................................................................................. 42 Jinma 254 Specifications..........................................................................................................................43 Jinma Crate Tractor Assembly ................................................................................................................ 46 Jinma JW-03 Backhoe Info ..................................................................................................................... 50 PIVET PINS................................................................................................................................... 50 Enlarge outrigger pads. ............................................................................................................... 51 Strengthen lower sub-frame. ......................................................................................................... 51 Stiffen up rear mount .................................................................................................................... 52 Version 0.2 Page 4 of 52

Jinma 200 series Tractor Users Manual MCE 2004.01 Index of Illustrations, drawings and photos. Figure 1. A 254 at the factory...................................................................................................... 8 Figure 2. Yancheng City.............................................................................................................. 8 Figure 3. Old Factory with dirt floors .......................................................................................... 8 Figure 4. New factory machine shop........................................................................................... 8 Figure 5. Engine assembly in the new plant................................................................................ 8 Figure 6. Map of Jiansu Province ............................................................................................... 8 Figure 7. Shear Point.................................................................................................................... 11 Figure 8. Pinch Points.................................................................................................................. 12 Figure 9. Crush Points.................................................................................................................. 13 Figure 10. Spring dangers............................................................................................................. 13 Figure 11. Old style instrument panel ........................................................................................... 17 Figure 12. Old style lower dash switches .....................................................................................17 Figure 13. New style electronic instrument cluster ....................................................................... 18 Figure 14. New style lower dash switches .................................................................................... 18 Figure 15. Driving Controls.......................................................................................................... 19 Figure 16. Ignition Switch ........................................................................................................... 21 Figure 17. Clutch cut away diagram............................................................................................. 29 Figure 18. Brake cut away diagram.............................................................................................. 30 Figure 19. TY-290 Engine............................................................................................................ 34 Figure 20. JM204 TY29 Engine with valve cover removed ........................................................ 34 Figure 21. Close-up of JM-204 TY290 engine head.....................................................................34 Figure 22. Y385 Torque Sequence, used for JM254/284............................................................. 35 Figure 23. TY20 Torque Sequence, used in JM184/204/224....................................................... 35 Figure 24. Hydraulic Filter Assembly...........................................................................................36 Figure 25. Hydraulic filter disassembly........................................................................................ 37 Figure 26. Hydraulic Filter Parts...................................................................................................37 Figure 27. Hoe Hydraulic Oil Filter .............................................................................................. 38 Figure 28. Hoe Hydraulic Filter o-ring......................................................................................... 38 Figure 29. Fuel Injector Oil filler (A) & Drain (C) ....................................................................... 40 Figure 30. Fuel Injector Breather (A) and Cap (B)...................................................................... 40 Figure 31. Fuel Injector Assembly................................................................................................ 40 Figure 32. Fuel Injector Steel Balls.............................................................................................. 40 Figure 33. Transmission Oil Drain............................................................................................... 41 Figure 34. Engine Oil Drain.......................................................................................................... 41 Figure 35. Hydraulic System Oil Drain........................................................................................ 41 Figure 36. JW-03 Backhoe showing modification points............................................................. 50 Figure 37. Flat bar details............................................................................................................. 50 Figure 38. JW-03 Pivot pins......................................................................................................... 50 Figure 39. Enlarged Outrigger Pads.............................................................................................. 51 Figure 40. Hoe Frame showing heavy reinforcement .................................................................. 51 Figure 41. Hoe frame damage....................................................................................................... 51 Version 0.2 Page 5 of 52

Jinma 200 series Tractor Users Manual MCE 2004.01 Figure 42. Hoe frame reinforcement fwd view............................................................................. 51 Figure 43. Hoe frame reinforcement after view............................................................................ 51 Figure 44. Hoe frame top link stabilizer ....................................................................................... 52 Version 0.2 Page 6 of 52

Jinma 200 series Tractor Users Manual MCE 2004.01 INTRODUCTION This manual is a general guide to provide the user with general information with respect to personnel and equipment safety, operational procedures and maintenance of your machine. This manual was developed to fill the requirement for a JINMA specific operations and maintenance manual. While Jinma tractors come with a set of 4 manuals, some of the language syntax is a little hard to follow. Sources of data Sources of data for this manual come from many places. They include , but are not limited to the following: http://www.johnstractor.homestead.com/, http://www.emerybuilt.com/ http://www.tractor-outlet.com/ http://www.china-tractors.com/ http://www.tractorpages.com/, http://chinabestproducts.com Factory Engine Operations Manual, Factory Tractor Operations and Maintenance Manual, Factory Tractor Illustrated Parts Breakdown Manual, Factory Engine Illustrated Parts Breakdown Manual. The Chinese Tractor Owner Association is a good place to lurk, ask questions and get/give support from/to others. http://www.ctoa.net Please read this manual carefully and keep in a convenient place for future reference. Do not hesitate to contact your local dealer for any questions concerning the tractor. Even if you obtained this tractor as a crate assembly project, a tractor dealer can provide skilled personnel, spare parts and all tools and equipment necessary for your service requirements. Most of all, a dealer will have the experience of working with tractors and small diesel engines. PARTS Parts are readily available for JINMA series tractors. The Internet is a good place to find sources of parts. http://www.jinmaparts.com is but one company selling parts for your machine. Any suggestions and or comments about this manuals contents, errors or omissions are most welcome. Please email or mail: Steven Bradshaw 1033 Braithwaite Drive Cobble Hill, BC Canada. V0R-1L0 brads@malacat.ca Version 0.2 Page 7 of 52

Jinma 200 series Tractor Users Manual MCE 2004.01 Yancheng Tractor Factory The Yancheng Tractor Factor is located, as you may guess, in the city of Yancheng, Jiangsu province, China, and is about 100 miles north of Shanghai. Yancheng is one of thirteen municipalities of Jiangsu province. Yancheng is situated by the Yellow sea. With the coastal marshland covering an area of 453,000 ha with rich resources, Yancheng is an important production center for clams, prawns and eels. The two natural protection regions of red-crowned cranes and David' s dear have been set up in Yancheng. The development of agricultural economy of the city is in full swing, making the city a new commodity grain and cotton base in China. The local industrial structure has been completed in Yancheng with industries like textiles, machinery, electronics, chemical, pharmaceutical, food processing and construction materials industries as its backbone. The arts and crafts, native and special products of the city are of unique styles. The tractor factory was originally built about 50 years ago. As you can see from figure 3, this factory was a less than ideal environment in which to build. As of the spring of 2002 all tractors were being built in a new factory. Average wage per person in Jiansu Prov for 2003 was 9200 Yaun (Cdn $1400). Pop. 70.2 Million Area: 1.03 x 10 5 Km 2 Version 0.2 Page 8 of 52 Figure 1. A 254 at the factory Figure 2. Yancheng City Figure 5. Engine assembly in the new plant Figure 3. Old Factory with dirt floors Figure 4. New factory machine shop Figure 6. Map of Jiansu Province

Jinma 200 series Tractor Users Manual MCE 2004.01 THE RULES Version 0.2 Page 9 of 52 • Know the controls and how to stop quickly. READ THIS MANUAL and instructions furnished with attachments. • Do not allow children to operate the machine. Do not allow adults to operate the machine without proper instructions. • Do not carry passengers. Don't mow when children and others are around. • Clear the work area of objects (wire, rocks, etc.) that might be picked up and thrown. • Disengage PTO and shift into neutral before attempting to start the engine. • Disengage PTO and stop the engine before leaving the operators position. • Disengage PTO and stop the engine before making any repairs or adjustments. • Disengage PTO and lower all attachments when not in use. • Take all possible precautions when leaving the vehicle unattended, such as disengaging the PTO, lowering all hydraulic attachments, setting the parking brake, stopping the engine and removing the key. • Do not stop or start suddenly when going uphill or downhill. Mow up and down the face of slopes; never across the face. • Reduce speed and exercise extreme cation on slopes and in sharp turns to prevent tipping or loss of control. Be especially cautious when changing direction on slopes. • Stay alert for holes, rocks, and roots in the terrain and other hidden hazards. Keep away from drop-offs. • Use care when pulling loads or using heavy equipment. a) Use only approved draw bar hitch points. b) Limit loads to those you can safely control. c) Do not turn sharply. Use care when backing. d) Use counterweights or wheel weights when suggested in this manual. • Watch out for traffic when crossing or near roadways. • When using any attachments, never direct discharge of material toward bystanders or allow anyone near the vehicle when in operation. • Handle fuel with care. a) Use approved container. b) Never remove the fuel cap of, or add to a running or hot engine. Read these safety rules and follow them closely. Failure to obey these rules could result in loss of control of vehicle, severe personal injury to yourself or bystanders, or damage to property or equipment. The triangle in the text signifies important cautions or warnings which must be followed.

Jinma 200 series Tractor Users Manual MCE 2004.01 Version 0.2 Page 10 of 52 • Open doors if the engine is run a confined space – exhaust fumes are dangerous. Do not run the engine indoors. • Keep the vehicle and attachments in good operating condition, and keep safety devices in place and in working condition. • Keep all nuts, bolts and screws tight to be sure the equipment is safe to operate. • To reduce the risk of fire, keep the engine and exhaust system free of grass, leaves or excessive grease. • The vehicle and attachments should be stopped and inspected for damage after striking a foreign object, and damage should be repaired before restarting and operating the equipment. • Do not change the speed governor setting or over speed the engine. • When welding, make sure that hoses are properly protected as sparks or molten material may puncture or weaken the tubes and sleeves, resulting in leakage or of oil, cooling liquid, etc. • Avoid using unsuitable, pressurized filling systems or fuel cans when filing tanks, as these may cause considerable spillage and leakage of liquids. • As a general rule, do not allow liquid fuels, lubricants, acids, solvents, etc. to come into contact with the skin. The majority of these products contain substances that are potential health hazards. • Modern lubricants contain additives. Do not burn contaminated fuel oils and/or oils used in conventional heating systems. • Avoid spillage when transferring used engine cooling liquids, engine and transmission lubricants, hydraulic oils, etc. Never mix used fuel oil with lubricants. Store safely until suitable disposal can be arranged according to national legislation or local regulations. • Modern anti-freeze liquids and solutions, e.g.: anti-freeze and other additives must be replaced every two years. They must not be left to be absorbed into the ground, but must be collected and disposed of in a suitable manner. • Any leakage or defect in the engine cooling or hydraulic systems must be repaired immediately. • Do not increase the pressure in pressurized systems, as this may cause component parts to burst. • When welding, make sure that hoses are properly protected as sparks or molten material may puncture or weaken the tubes and sleeves, resulting in leakage or of oil, cooling liquid, etc.

Jinma 200 Series Tractor Users Manual

You're Reading a Preview

Recently Viewed