Mahindra JINMA-200, Operation Manual

Page 1: ...JINMA SERIES TRACTOR OPERATION MANUAL JINMA 200 JINMA 204 JINMA 250 JINMA 254 JINMA 300A JINMA 304A MAHINDRA YUEDA YANCHENG TRACTOR CO LTD ...

Page 2: ...rformance wide thread driving tyres of good adhesive force and low pressure and reliable crankpin type and circulating ball type but also have hydraulic steering gear the users can choose either of them The products are featured by their favourable power relatively hight traction force compact contruction high transmission efficiency easy operation convenient repair and maintenance economical oil ...

Page 3: ...hibited to turn sharply with one side braking while tractor runs at high speed in order to avoid overturning or parts damage 5 Bolts or nuts of wheel disc and of other important parts should be checked regularly and be tightened if they are loose 6 During transferring the tractor with a mounted implement it is not allowed to drive the tractor at high speed in order to avoid damaging hydraulic lift...

Page 4: ...lass maintenance 20 4 Third class maintenance 20 5 Fourth class maintenance 20 6 Maintenance in winter 21 7 Maintenance for storage of a long time 21 Ⅳ Chapter Adjustment of Tractor 22 1 Adjustment of clutch 22 2 Adjustment of main drive 24 3 Adjustment of differential lock 27 4 Adjustment of brake 28 5 Adjustment of front axle 30 6 Adjustment of front drive axle 31 7 Adjustment of wheel tread 33 ...

Page 5: ...pendix 59 1 Wiring diagram of the electrical system 59 2 Accessaries for customers to order 59 3 Distribution diagram of rolling bearing and transmission system of JM series tractors 61 4 Specifications and distributions of oil seals in JM series tractor s chassis 63 5 Sizes of hitch system 65 6 OECD approval No of JM series tractors 67 ...

Page 6: ...2 2 75 0 2 3 0 0 2 2 8 0 2 3 0 0 2 2 75 0 2 3 0 0 2 2 8 0 2 3 0 0 2 Weight kg Construcional weight Min working weight 1040 1160 1140 1270 1040 1060 1140 1270 1170 1290 1270 1400 Rated traction force N 4000 4800 5200 5980 5200 5980 Normal speed km h six six six six eight eight Forward 1 st 2nd 3rd 4th 5th 6th 7th 8th Reverse 1st 2nd 1 99 0 37 3 94 0 73 6 57 1 22 9 21 1 72 18 2 3 39 30 36 5 66 1 58 ...

Page 7: ...drive Internally meshed single spur cylindrical gear Walk and operatin g system Frame type Frameless rigid connection Front axle type inverted U pipe balancing arm side bevel gear drive inverted U pipe balancing arm side bevel gear drive inverted U pipe balancing arm side bevel gear drive Pendulum angle of front axle 12 8 12 8 12 8 Tyres Front wheel Rear wheel 4 00 16 8 3 24 6 00 12 8 3 24 5 00 15...

Page 8: ...000 610 Safety valve release pressure MPa 16 0 1 6 Suspension mechanism Connection type of implements rear mounted point hitch category 0 Ⅰ rear mounted point hitch category Upper link hole diameter mm φ19 5 44 Lower link hole diameter mm φ22 5 35 Traction device Traction ground clearance mm 470 495 Traction pin diameter mm Φ20 Power take off Rear P T O shaft Nonindepender 540r min or semi indepen...

Page 9: ...rature gauge 12V 40 100 pressure gauge 0 1 0 MPa Head lamp ND118 80T 20 8W 12V Rear light WD115 2 20 8W 12V Direction light FT12 8W 12V Electric horn DL87 12 Main filling capacity L Fuel tank 19 19 19 19 24 24 Engine oil sump 5 Front drive axle 4 5 6 6 6 Transmission box 11 14 11 14 11 14 Lifter 9 14 Steering gear 0 4 Cooling water 10 or 12 4 ...

Page 10: ...should be drained out Component Season and ambient temperature Oil specification Fuel tank Summer ambient temp above10 No 0 10 light diesel fuel GB252 87 Winter ambient temp below10 No 20 light diesel fuel GB252 87 Engine sump Lifter Oil pan of air cleaner Injection pump Hydraulic steering gear Ambient temp below 0 No 20 diesel engine oil GB5323 85 Ambient temp at 0 25 No 30 diesel engine oil GB53...

Page 11: ...ry C Check the lubricating oil level and refill to stipulated level if insufficient D Inject grease into lubricating points E Fill with fuel and cooling water F Check toe in 4 10mm and tire inflation pressure readjust or reinflate if necessary G Inspect the connections of battery and wires of electrical system 2 Idle running in of the engine After the engine is started in accordance with specified...

Page 12: ...he lubricating oil in the engine sump while it is still warm Wash the sump and oil filter with diesel fuel After the diesel fuel has been out refill the sump with new lubricating oil to specified level B Drain out the lubricating oil in the transmission box hydraulic system and front drive axle while it is still warm Then fill them with diesel fuel of proper quantity and run the tractor in 2nd for...

Page 13: ...edal then the clutch is disengaged 7 Decompressing lever Reduce the pressure in the cylinders to make the engine start easier 8 Extinguishing lever Fuel cut off rod To make the engine stop 9 Single position switch Pull the switch out the rear work light is turned on and push the switch in it is turned off 10 Turning signal switch Turning the switch to the left or right the left or right turning si...

Page 14: ...9 Fig 2 1 Controls and Instruments ...

Page 15: ...ever Engage or disengage P T O power 25 Differential lock lever Used to move right claw to make differential lock disengaged or engaged so that the two driving wheels have different speeds or not 26 Hydraulic control lever When the lever is pushed or pulled backward forward or into vertical position respectively the hitch is lifted lowered or in neutral position 5 Control and operation of the trac...

Page 16: ...gain D When switch starting is successful turn the starting switch counterclockwise to the charging position of battery E It is not necessary to decompress the engine while switch starting in summer Filling the radiator with hot water or the oil sump with heated engine oil can be used as starting aids in winter 2 Starting the tractor After the engine is started run it at moderate speed for 5 10 mi...

Page 17: ...ed condition of clutch C In transportation or running on highway lock the left and the right brake pedals together with brake lock plate D In field operation one side braking can be used to reduce turning radius but it is prohibited to use one side braking for sharp turning when the tractor is running at high speed or is used for transportation on highway so as to prevent overturning and protect c...

Page 18: ...mbient temperature is below 0 screw of the radiator cap and turn on the water drain cock on the bottom of the radiator and on the cylinder block to drain out water at idle engine speed so as to protect the body and radiator from being frozen not includingadding anti icing fluid 5 Safety regulations for operation Safety regulations are very important for protecting drivers and tractors from hazard ...

Page 19: ...e to the PTO shaft B Put the gear shifting lever at the neutral position C Depress the clutch pedal fully then shift the PTO control lever to the engaged position D Release the clutch pedal slowly and the driven machine will run First let the driven machine run at slightly open throttle for a while to ensure that nothing is wrong with the driven machine Then make the throttle wide open and put the...

Page 20: ...ed properly according to the weight of the implement and hardness of soil surface in order to prevent the implement from being seriously impacted and damaged Turn the lowering speed adjusting valve clockwise the lowering speed will reduce turn the valve counterclockwise the lowering speed will increase D Operation of hitch system Adjust the implement according to the implement operation manual bef...

Page 21: ...sal joint shaft after attachment there should be about 10mm axial clearance between PTO shaft and universal shaft 3 Using the differential lock In tractor transportation and operation if one drive wheel slips greatly and the tractor can not move forward operate the differential lock according to the following steps A Depress the clutch pedal move the gear shifting lever to the low range gear posit...

Page 22: ...ery C Check the height of electrolyte level and specific gravity In normal use if the height of electrolyte level is below 10 15mm distilled water should be poured into it in time Well water or river water can t be used So as to prevent impurity from entering electrolyte If electrolyte overflows much under unusual conditions it can be added The density of electrolyte in electrolytic cell should be...

Page 23: ...rter clean and the contacts between wires in good condition B The time for each starting should not be over 10 seconds The shortest interval between two startings must be more than 2 minutes If the engine can not be started after several startings the trouble should be found out and removed then the engine can be restarted C If the engine is started in winter it should be preheated and then can be...

Page 24: ...xamined 4 Check whether there is leakage of oil water and air remove if necessary 5 Check the tire pressure and inflate if necessary 6 Grease the points according to the table 2 1 Before greasing the sludge and water should be squeezed from the lubricating points 7 Check the specified tools supplied 2 First class maintenance Carry out the following maintenance after every 50 hours of operation 1 C...

Page 25: ... lifter check the oil cleanliness degree flush the inside of lifter house and replace with fresh oil if necessary 6 Check and adjust front wheel toe in The toe in should be 4 10 mm Check the clearance of the front wheel bearing and adjust if necessary Replace the grease in the front wheel hubs 7 Check the free travel of the steering wheel The free angle should be less than 15 adjust if necessary 8...

Page 26: ...stop for a long time after operation the water without anti icing fluid in it in the cooling system should be drained out Water temperature of draining out is 50 55 4 Choose fuel and lubricating oil according to air temperature or season 5 In cold season in order to start the engine easily the tractor can be stored in a warm storehouse 7 Maintenance for storage of a long period The tractor for sto...

Page 27: ...ly consists of three parts driving part driven part and controlling part Driving part rotates with the engine flywheel only when the clutch engages can the driven part rotate with the engine Dual stage clutch should be adjusted on a fixture The adjusting steps are as follows Adjust the length of adjusting bolt 11 to make the distance between 3 release levers 19 and the end faces of PTO clutch pres...

Page 28: ...ch pedal loosen nut 10 then turn adjusting bolt 11 to make the working travel under release rock arm 12 is 25mm then tighten nut 10 2 Adjustment of single stage clutch Fig 4 2 is single disk and dry single stage clutch It is made up of clutch spring 1 clutch driven plate 2 clutch pressure plate 3 release lever 6 adjusting nut 7 release bearing 9 and its operation mechanism The adjuting methods of ...

Page 29: ...hes the free travel of the clutch pedal L 8 12 mm while the corresponding free travel under the release rock arm 17 is L1 3 5 5 5 mm C Position limit adjustment of working travel of clutch pedal Turn limiting adjusting bolt 18 until the working travel under release rock arm 17 is L2 13 17mm In operation the free travel of the clutch pedal should be often checked and ensured 2 Adjustment of main dr...

Page 30: ... meshing backlash and meshing print The required mesh backlash is 0 1 0 25 mm The ideal mesh prints distribute in the middle of the working teeth surface and are slightly near the small end of the teeth meshing prints are like spots meshing print height is not less than 50 of tooth height the length of meshing print is not less than 60 of tooth length B Inspection of mesh backlash and mesh print a...

Page 31: ...spiral direction of the bevel pinion is right handed when the tractor forwards the force is applied on the concave face of the bevel pinion the readlead paint should be smeared on the convex face of the bevel gear while the tractor reverse the force is applied on the convex face of the bevel pinion the red lead paint should be smeared on the concave face of the bevel gear Table 4 1 Adjustment of m...

Page 32: ... only the mesh backlash increases and this increase of backlash due to gear wear need not be adjusted But after the overhaul of the tractor or when replacing a new pair of main drive gears or bevel bearing the mesh print and backlash should be ensured at the same time by careful adjustment Note As the bevel pinion and the bevel gear are a pair of matched gears be sure not to make pairs in disorder...

Page 33: ... too small and keep the brake in semi braking state the brake case also generates heat c Left and right braking force is unidentical and tractor yaw motion appears 1 Adjustment of block brake shoe brake A Free travel adjustment of brake pedal is the displacement measured from the highest position of the pedal when resistance is felt by pressing the pedal The travel should be in the range of 55 65 ...

Page 34: ...locking nut 9 Subsequently check in the 3rd gear firstly after above adjustment has been done the check in the 4th gear again 2 Adjustment of disc brake A Free state adjustment of disc brake pedal is the displacement measured from the highest Loosen the outer locking nut M10 5 on adjusting rod 1 and turn the inner nut M10 4 to change the mounting angle of the rock arm 2 through the longitudinal mo...

Page 35: ...nge can not perfectly make the free state and brake state out they can be adjusted through increasing or reducing the brake cover gaskets 11 between brake cover 12 and brake case 10 If the brake travel is too small increase the gaskets if the brake travel is too big reduce or remove the gaskets Fig 4 6 C Brake yaw motion adjustment Refer to the adjustment of shoe brake 5 Adjustment of front axle 1...

Page 36: ... of the two wheels B is the distance between the rearmost ends of the two wheels at the same horizontal plane through the centers of the two wheels circumference c Loosen the locking nuts 1 and 3 on both sides of the knuckle rod 2 turn the knuckle rod to make B A 4 10mm then retighten knuckle rod 2 with nuts 1 and 3 6 Adjustment of front drive axle 1 Adjustment of main drive Fig 4 9 During assembl...

Page 37: ...justment of side reduction gear pairs Fig 4 10 During assembling choose gasket 13 of driving shaft cover to keep the mesh backlash of side reduction gear pairs among 0 2 0 4mm and ensure meshing contact traces ...

Page 38: ... ensure meshing contact traces 7 Adjustment of wheel tread 1 Adjustment of front wheel tread The front wheel treads of Agracat Series Tractors have the following two types adjustable wheel tread and non adjustable wheel tread The adjustable wheel tread is adjusted in step through extension sleeve housing The adjusting range is 970 1270mm Every step clearance is 100mm ...

Page 39: ...ght and left driving wheels The adjustment range of the first step wheel tread is L1 L2 the normal wheel tread is L2 The adjustment range of the second step wheel tread is L3 L4 see Fig 4 11 Numerical Ⅰ value of L1 L4 can be referred to in chapter 8 Adjustment of steering gear There are three kinds of steering gear of Agracat Series Tractors crankpin type Fig 4 12 circulating ball type Fig 4 13 an...

Page 40: ...ower moving play of the steering worm be not more than 0 1mm through increasing or reducing the quantity of adjusting shim 11 B Adjustment of mesh clearance of steering worm and crankpin During operation the mesh clearance will increase due to the wear out of the steering worm and crankpin and the idle angle of the steering wheel also increases When the idle angle of the steering wheel is more tha...

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Page 42: ...eering worm be not more than 0 1mm through increasing or reducing the quantity of adjusting shim 7 B Adjustment of mesh clearance of rock arm shaft with steering worm and nut assembly and fan teeth of rock arm shaft During operation the mesh clearance will increase due to the wear out of fan teeth of the rock arm shaft with steering worm and nut assembly and the idle angle of the steering wheel wi...

Page 43: ...ing type needle wheel mesh pair The rotor has 6 short outer pendulum string curve teeth of equal distance while the stator has 7 arc needle teeth During working the stator is still and the rotor rotates round the center of the stator at the radius of a certain eccentric distance When the rotor rotates round center of the stator revolution it also rotates round its axial line in opposite direction ...

Page 44: ... 160 164 tractors The gear pumps are mounted on the back end face of the right side of the gear case of the diesel engine front which are driven by engines The gear pump is made up of a pair of outside mesh shaft gear 5 and 6 gear body 2 sleeve 7 and rear cover 1 and front cover 3 The working principle of the gear pump is as Fig 4 16 Take left handed gear pump as example After starting the engine ...

Page 45: ...position of the sleeve is decided by the force applied on the sleeve The width of the pump body is 0 09 0 18mm bigger than the width sum of gear and sleeve After mounting the front and rear cover are pressed tightly on the pump body the seal ring between the covers are compressed and the sleeve is pressed tightly on the two end faces of the gear thus not big clearance forms between sleeve and cove...

Page 46: ...flow direction designated by the arrow in the Fig 4 19d then the implement is lowering In such case the oil from oil pump into direction exchange valve still flows back into oil tank through returning oil cavity A When the main control valve is pushed to lifting position from neutral position Fig 4 19c the returning oil cavity A closes while entering oil cavity B opens Then the oil from oil from o...

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Page 48: ...l in the cylinder flows back into oil tank through main control valve 5 and the implement begins to fall down With the implement falling gradually stop pin 2 fixed on the stop plate of the lift shaft and the lift shaft together rotate around the lift shaft counterclockwise and slip along return push rod 4 after they slip to contact the lowering position limiting stop block 3 fixed on the return pu...

Page 49: ...ng state all the time While raising the implement push operation handle 10 to lifting position and then position locating steel ball falls into position locating slot A Fig 4 20 main control valve 5 moves left to lifting position The implement begins to rise with the implement rising gradually meanwhile return stop pin 2 rotates around the lift shaft clockwise when the stop pin slips to contact li...

Page 50: ...pward until the clearance between the end of inner lift arm 3 and stop pin 4 is not less than 5mm insert a steel pad through the hole vent plug 5 control this clearance by the pad thickness Adjust the clearance between stop block 6 and stop pin 7 to be 9 10mm then fix the stop block on the return push rod 8 with bolt and nut Adjustment of the lowering position Set the control lever 1 at the neutra...

Page 51: ...ment of safety valve Safety valve has been adjusted before leaving the factory In general dismounting in operation is not permitted anyhow If the readjustment is necessary it should be done on special pressure test stand The oil for test is HC 8 SY1152 77 the oil temperature should be controlled as 65 5 When the press screw plug of safety valve is rotated clockwise the higher opening pressure is g...

Page 52: ...rotate around axle pin 13 to make adjusting bolt 12 press down brake pull rod 9 compress balance spring 7 push core rod 5 compress return spring 4 push valve seat assembly 3 aside compress valve seat spring 2 open high pressure air passage and at this moment the compressed air of receiver from hole A to valve seat hole then to mouth of hole B and continuously respectively enter the left and right ...

Page 53: ...e of the rubber of valve seat assembly 3 and slightly grind the compressed prints on fine abrasive cloth if necessary Generally after 1000 hours work of the valve should dismantle and clean all the parts grind the valve seat adjust the maximum pressure of brake and check the seal performance after assembling Adjustment of brake pressure When the brake pedals are stepped into the lowest place the m...

Page 54: ...damaged piston rings gummed up or worn nut Lap inlet or exhaust valve Adjust the valve clearance Renew cyliner head gasket or piston rings if necessary 6 Shortage of the battery electricity Recharge or replace the battery Cause Remedies 1 Air filter or fuel filter choked Clean it in light fuel or kerosene 2 Beginning of fuel delivery incorrect Adjust according to the recommended procedure 3 The fu...

Page 55: ...settle the problem 3 Sudden oil pump failure or oil filter stopped up or relief valve by pass valve went wrong Repair or change oil pump Clean or change the element Cause Remedies 1 Engine overheated due to lack of cooling water Check regularly if the cooling water is enough 2 Cylinder overheated because of water scale Scour out the water jacket 3 Engine overloaded Follow the regulations of operat...

Page 56: ...uel Repair the nozzle assembly Calibrate the pressure Cause Remedies 1 Low tension of v belt Adjust the tensionor change the v belt 2 Engine overheated Lighten the load 3 High exhaust temperature because of fuel delivery delayed or leakage of fuel from injector Repair the fuel delivery system Cause Remedies 1 Friction disc surfaces stained with oil Clean the surface with diesel and eliminate leaka...

Page 57: ...rs 2 Gear teeth breakage Replace gear 3 Bearing worn out excessively or damaged Replace bearings 4 Improper meshing backlash of main drive gears Readjust it to required numerical valve Cause Remedies 1 Too small bearing clearance or meshing clearance of bevel gears Readjust to required mumerical value 2 Lack of oil Fill lubrication oil to required level 3 Poor quality of oil Clean with diesel add ...

Page 58: ...ring of brake shoes weakened Replace spring 2 Too small clearance between brake linings and drum Adjust pedal free travel Cause Remedies 1 Excessive clearance between crankpin and worm or steering screw worm and nut Readjust the clearance or replace the worn parts 2 Low inflation pressure in front tires Inflate as specified 3 Insufficient oil supply of oil pump Choose suitable oil pump or check th...

Page 59: ...r ball joint seat 3 Pendulum shaft bush worn out Replace bush 4 Steering knuckle shaft bush worn out Replace shaft bush Cause Remedies 1 Improper adjustment of front toe in Readjust toe in 2 Low inflation pressure of tyre Inflate tyre to specified pressure 3 Driving wheel mounted reversely Remount the driving wheel Cause Remedies Adjusting valve locked Loosen adjusting valve Cause Remedies 1 Cylin...

Page 60: ...ngs and cylinder lining of air compressor seriously damaged Replace piston rings and cylinder lining 5 Filter blocked Clean filter 6 Safety valve is not completely closed or is not flexible Check and repair or replace safety valve 7 Cylinder head studs of air compressor is loose or cylinder gasket leaks Tightly screw cylinder head studs or replace cylinder gasket Cause Remedies 1 Impurity between ...

Page 61: ...oint Poor contact of solenoid switch Check and repair solenoid switch Battery insufficient or voltage too low Recharge battery after checking 3 Starter runs with starting pinion unmeshed and pinions knocked at each other Too small travel of armature Screw the connecting screw of armature in for 2 3 rings Cause Remedies 1 Generator fails to generate current Connecting wires loose broken short circu...

Page 62: ... part Find out interference adjust mounting position Bearing damaged Replace bearing Rotor knocking against stator Repair 5 Burnt smell of generator Damaged diode cause one fase or two fases burnt Replace Stator knocking against rotor core and burned and cause short circuit of winding of stator and rotor coil Repair or replace coil Ineffective regulator or too high of regulated voltage overloaded ...

Page 63: ...rge battery or overdischarge battery to make plate impurity enter electrolyte then pour electrolyte out and clean with distilled water and refill with new electrolyte and recharge 3 Charge capacity of battery distinctively reduces low discharging voltage high charging voltage low indensity of electrolyte and plates sulphurized Frequently insufficient electric power Charge for a long time with smal...

Page 64: ...pter Appendix 1 Wiring diagram of the electrical system 2 Accessories for customers to order Customers may order and purchase the following accessories of the tractors from our factory according to requirements ...

Page 65: ...ty Purpose 1 High lugged tyres One pair Used in paddy field 2 Turf tyres Two pairs For garden use 3 Cab 1 Improve driver s working condition 4 Protective roll bar 1 Ensure safety of drivers 5 Belt pulley 1 For fixed operation ...

Page 66: ...61 3 Distribution diagram of rolling bearing and transmission system of Jm series tractors ...

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Page 68: ...r of reverse shaft Driving gear shaft of final transmission Front bearing seat of 2nd shaft Out ring of bearing seat Inner of driving shaft bushing 1 2 1 1 2 1 2 2 GB3452 1 82 O ring 9 5 2 65 10 2 65 11 2 2 65 Creeper shifting fork shaft Power shifting fork shaft of transfer box Creeper shifting lever 1 1 2 JB2600 80 Oil seal GB9877 1 SG25 40 8 FB25 47 7 Oil seal seat of transfer box Oil seal seat...

Page 69: ...ight side reduction housing Driving shaft Left right side reduction housing Driving shaft 2 2 2 2 2 GB3452 1 82 O ring 21 2 3 55 28 3 55 34 5 3 55 63 3 55 69 3 55 77 5 3 55 82 5 3 55 Driving bevel gear Inner of front pendulum shaft Upper bearing cover Middle of front pendulum shaft Back support seat assy Inner of bearing seat of driving bevel gear Middle of bearing seat of driving bevel gear 1 1 2...

Page 70: ...pool rod Joint of distributor and lifter 1 2 1 1 1 GB3452 1 82 O ring 63 5 7 63 5 7 Outside of piston Inside of cylinder head 1 1 GB3452 1 82 O ring 9 2 65 9 2 65 15 2 65 Safety valve seat Inside of distributor handle shaft Lower of pressing screw plug of distributor 1 1 1 Model Parameter JM200 JM204 JM250 JM254 H 690 705 702 702 H1 200 146 180 180 h 470 470 495 495 R 497 5 497 5 525 525 R1 545 60...

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Page 72: ...f tractors to which the protective structure are fitted Model JM 180 JM 200 JM 204 JM 254 OECD Approval No Full code 1354 1563 1657 1650 Model OECD approval number JM 180 NT ROPS R S0110 4 JM 184 NT ROPS R S0110 3 JM 200 NT ROPS R S0110 2 JM 204 NT ROPS R S0110 1 ...

Page 73: ...A YUEDA YANCHENG TRACTOR CO LTD Add 90 South Wengang Road Yancheng City Jiangsu Province Tel 0086 515 88231130 88231131 Fax 0086 515 88229791 Postcode 224002 Tttp www jm tractor com E mail tractorobd yantuo cn ...