DongFeng ZB Series User manual

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Factory Direct Tractors
Operator’s Manual
ZB 65 / 85

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FOREWORD
Congratulations on your purchase of a new DongFeng Factory Direct Tractor.
DongFeng is Chinese for ‘DongFeng’.
The ZB Series is built to exacting DongFeng standards at the Changzhou Dongfeng Agricultural Machinery
Factory. They are designed to meet the needs of theAustralian Lifestyle Farmer while representing outstanding
value. Safety is our highest priority and your tractor is tted with a certied Roll Over Protective Structure
Performance is taken care of with a four cylinder, direct inject diesel engine that provides high torque, reduced
vibration and low noise.
Great features include, four wheel drive, hydraulic power steering and two-speed P.T.O..
A number of implements can be tted to your tractor enabling you to take on a wide variety of tasks around your
farm. Hanmey implements are ideally suited to your tractor. Find out more at hanmey.com.au
DongFeng Tractors are subject to continuous improvement and change without notice. Therefore, there may
be some difference between the manual and illustrated parts catalogue and your actual tractor. Dealers or
operators are requested to provide the serial number, stock number (if available) and date of manufacture of
the tractor when placing an order for spare parts. This helps to ensure the correct part is provided.
Take the time to read this manual carefully for your safety and awareness of your machine. With a little care
you can look forward to a lifetime of service on a lifestyle property.
DongFeng Tractors,
Australia.
November 2012

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CONTENTS
SPECIFICATIONS
SAFETY PRECAUTIONS
SAFETY FIRST
FRONT END LOADER SAFETY
1. REQUEST FOR DEALER SERVICE
2. INSTRUMENT PANEL AND CONTROLS
2.1 Instrument Panel Display
2.2 Controls
3. ‘RUNNING-IN’
3.1 Running-in the engine without load
3.2 Running-in the tractor without load after warm up
3.3 Running-in the tractor with load
3.4 Service after running-in
4. OPERATING INSTRUCTIONS
4.1 Pre-start checks
4.2 Starting and stopping
4.3 Driving
4.4 Check during driving
4.5 Operating the differential lock
4.6 Control and usage of tractor’s working devices
5. MECHANICAL ADJUSTMENT
5.1 Engine
5.2 Clutch
5.3 Wheel adjustments
5.4 Power steering
5.5 Brakes
5.6 Electrical system
5.7 Final drive system
6. TECHNICAL MAINTENANCE
6.1 Oil and lubrication
6.2 Maintenance schedule
6.3 Tractor storage
6.4 Maintenance service
6.5 Maintenance check list
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CONTENTS
7. MAINTENANCE
7.1 Fuel
7.2 Engine Oil level check and replacement
7.3 Transmission oil
7.4 Changing front axle case oil
7.5 Grease before operation
7.6 Radiator
7.7 Tyre pressure
7.8 Air cleaner
7.9 Battery
7.10 Three point linkage adjustment
8. TROUBLE-SHOOTING GUIDE
8.1 Engine
8.2 Chassis
8.3 Electrical system
9. LOADER OPERATION
9.1 Tractor preparation
9.2 Loader attachment and removal
9.3 Operation the loader
10. LOADER MAINTENANCE
10.1 Maintenance
10.2 Storing at the end of season
10.3 At the start of a season
10.4 General torque specication
11. LOADER TROUBLE SHOOTING
12. LOADER PARTS
12.1 Bucket Assembly
12.2 Attachment assembly
12.3 Main Frame assembly
12.4 Mounting assembly
12.5 Hydraulic system assembly
Appendix 1 Wiring Diagram
Appendix 2 Steering Cylinder Diagram
Appendix 3 Service Flow Chat
Appendix 4 Warranty Flow Chart
Maintenance record
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Specications
Tractor Model ZB65 ZB85
Drive type: 4WD
Horsepower: 65HP 85HP
Overall length (front weight to link end): (mm) 3890
Overall width (outer wheel tread): (mm) 1830
Height to R.O.P.S (top): (mm) 2550
Height to canopy (top): (mm) 2585
Height to steering wheel: (mm) 1750
Ground clearance: (mm) 320
Tractor weight with ballast: (kg) 3000 3200
Minimum turning radius: (m) 4.1
Speed: forward (km/hr) 1.57-36.61
backward (km/hr) 1.60-36.81
Engine Model LR4B3-23 LR4M5-23
Type: Direct injection, vertical Liquid Cooled 4 Cyl Diesel
Gross power (12hr rated power kw/hp): 48.0/65 62.0/85
Cylinders: 4 Cyl
Bore and stroke: (mm) 108 X 125 110 X 135
Compression: 17.0 : 1.0
Displacement: (L) 4.58 5.13
Speed rated at: (rpm) 2300
Gearbox: Synchromesh
Gears: 4 x (3+1)
12 Forward, 4 Reverse
Brake type: Wet Multi Disc
Clutch type: Dry Type Dual Stage
Rear differential lock: Mechanical
P.T.O. type: Live
P.T.O. rotating speed: 540/1000
P.T.O. kW/HP: 43.6/58.5
3PL capacity at Ball End: (kg) 1200kg (cat 2 linkage)
Hydraulics: Main pump: 38L/min
Power steer pump: (L) 2L
Fuel capacity: (L) 60
Engine Oil: (L) 10
Transmission Oil: (L) 25
Hydraulic Oil Reservoir: (L) 15
Front Differential Oil: (L) 7
Front Hubs Oil: (L) 2 X 1
Front tyre size - Agricultural: 11.2-24
Rear tyre size - Agricultural:
Front tyre size - Turf
Rear tyre size - Turf
16.9-30
12.4-24
16.9-30
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S-2
Front End Loader Specications
Loader attachment model BL-65 BL-85
AOverall length (mm)
(With bucket on the ground) 3170 3170
BBucket width (mm) 1840 1840
COverall height (mm)
(With bucket on the ground) 1655 1655
DClearance with bucket dumped 2118 2118
EMaximum lifting height (mm)
(From ground to bucket pivot) 2888 2888
FReach the bucket (mm)
(Bucket fully lifted and at 45° dumping angle) 800 800
GBucket dumping angle 76º 76º
HBucket rollback angle 32º 32º
LDepth of bucket (to back of inner shell) (mm) 770 770
MHeight of bucket (mm) 545 545
NDepth of bucket (to pivot pin) (mm) 970 970
Maximum opening angle of clamping bucket 88º 88º
Bucket cubage (m3)0.38 0.38
Carrying capacity (kg) 1000 1000
Mass of loader attachment (kg) 925 925
Minimum operating ow required 20L/min 20L/min
Maximum operating ow allowed 35L/min 35L/min
Minimum operating pressure required 10MPa 10MPa
Maximum operating pressure allowed 16Mpa 16Mpa

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Safety Precautions
• Recognize safety information
This is a safety — alert symbol. When you see this symbol on
your machine or in this manual, it is to alert you to the potential
for personal injury. Follow recommended precautions and safe
operating practices.
• Warnings and cautions
DANGER, WARNING, and CAUTION — is used in this safety
manual to alert you to safety issues. DANGER identies the most
serious hazards. DANGER or WARNING safety signs are located
near specic hazards. General precautions are listed on CAUTION
safety signs. CAUTION also calls attention to safety messages in
this manual.
• Follow safety instructions
Carefully read all safety messages in this manual and on your
machine. Keep safety signs in good condition. Replace missing or
damaged safety signs. Be sure new equipment components and
repair parts include the current safety signs. Replacement safety
signs are available from your DongFeng dealer.
Learn how to operate the machine and how to use the controls
properly. Do not let anyone operate without instruction. Keep your
machine in proper working condition.
Unauthorized modications to the machine may impair the function
and/or safety and affect machine life.
If you do not understand any part of this manual and need
assistance, contact your DongFeng dealer.
• Key start your tractor only
Avoid possible injury or death from machinery runaway.
Do not start engine by shorting across starter terminals.
Machine will start in gear If normal circuitry is bypassed.
NEVER start engine while standing on the ground. Start engine
only from operator’s seat, with transmission in neutral or park.
Safety Precautions
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Safety Precautions
• Use seat belt and foldable ROPS properly
Only operate the tractor when the ROPS is locked out in the ‘up’
or extended position, ALWAYS use your seat belt to minimize the
chance of injury from an overturn accident.
Only fold the ROPS to access low clearance areas. DO NOT
operate the tractor with the ROPS down or not properly installed.
DongFeng Tractors are equipped with a foldable Roll-Over
Protective
Structure (ROPS). The ROPS (A) should be kept in the ‘up’ or
extended position (as pictured) with lock out pins (C) retained with
R-clips (B), except when it is necessary to fold it for low clearance
access.
A ROPS
B R-clips
C Lock out Pin
• Handle chemicals safely
Direct exposure to hazardous chemicals can cause serious injury.
Potentially hazardous chemicals used with DongFeng equipment
include such items as lubricants, coolants, paints, and adhesives.
Before you start any job using a hazardous chemical, you should
know exactly what the risks are and how to do the job safely. Then
follow procedures and use recommended safety equipment.
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Safety Precautions
• Operate Tractor Safely
Features designed into your tractor
make operation Safer and let it perform
a wide variety of jobs. Use your tractor
only for specied jobs it was designed to
perform: implement carrier, load mover,
remote power source, or transport Unit
- not a recreational vehicle.
Careless use or misuse can result in
unnecessary accidents. Be alert to
hazards of tractor operation.
Understand causes of accidents and
take every precaution to avoid them.
Most common accidents are caused
from:
• Tractor misuse.
• Improper starting procedures
• Crushing and pinching during hitching
• Collisions with other motor vehicles
• Getting entangled in P.T.O. shafts
• Falls from tractors
Avoid accidents by taking the following
precautions:
Before dismounting, put the
transmission in NEUTRAL and APPLY
the PARK BRAKE. Leaving the
transmission in gear with the engine
stopped will NOT prevent the tractor
from moving. Be sure everyone is clear
of the tractor and attached equipment
before starting the engine.
Never try to get on or off a moving
tractor.
When the tractor is left unattended,
place the transmission in NEUTRAL,
apply the park brake, lower implements
to the ground, stop the engine and
remove the key.
S-4
1. Read Operator’s manual
before operating this tractor.
2. Keep all shields in place.
3. Hitch towed loads only to
drawbar to avoid rearward
upset.
4. Make certain everyone is
clear of machine before
starting engine or operation.
5. Keep all riders off tractor
and equipment.
6. Keep hands, feet and
clothing away from power-
driven parts.
7. Reduce speed when turning
or applying individual brakes
or operating around hazards ,
on rough ground or steep
slopes.
8. Couple brake pedals
together for road travel.
9. Use ashing warning
lights on highway unless
prohibited by law.
10. Stop engine, lower implement
to ground and shift to “PARK”
or set brakes(s) securely
before dismounting.
11. Wait for all movement to stop
before servicing machinery.
12. Remove key if leaving
tractor unattended.
!CAUTION

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Safety Precautions
• Hillside safety
Always wear your seat belt with the ROPS in the up
extended position.
Avoid holes, ditches, and obstructions which could cause
the tractor to tip, especially on hillsides. Avoid sharp, uphill
turns.
Never drive near the edge of a gully or steep embankment,
as it might cave in.
Driving forward out of a ditch or up a steep slope could
cause the tractor to tip over rearward. Back out of these
situations if possible.
While mechanical front wheel drive greatly increases
traction, it DOES NOT increase the stability of the tractor
With mechanical front wheel drive engaged, the tractor can
climb steeper slopes than a two wheel drive tractor can
negotiate, but it does not become more stable. Use extra
caution when negotiating steep slopes in four wheel drive.
Danger of overturn increases greatly with a narrow wheel
track, at high speed, and on slopes.
Hitch towed loads only to the drawbar. When using a chain,
take up the slack slowly.
• Hearing safety
Prolonged exposure to loud noise can cause hearing loss
or impairment.
Wear a suitable hearing protective device such as earmuffs
or earplugs to protect against hearing loss from loud noise.
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Safety Precautions
• Use low gear on hills
Shift to a low gear before descending a steep hill. This
improves your control of the tractor with little or no braking.
Use engine braking to reduce speed before applying the
tractor brakes. Run-away tractors often tip over. Never
coast downhill.
When driving on icy, wet or graveled surfaces reduce
speed and be sure the tractor is properly ballasted to avoid
skidding and loss of steering control. For best control,
engage mechanical front wheel drive (if equipped).
Additional ballast may be needed for transporting heavy
linkage mounted implements. When the implement is
raised, drive slowly over rough ground, regardless of how
much ballast is used.
• Operator only
Only allow the operator on the machine. Keep riders off
Riders or passengers on the machine are subject to injury
such as being struck by foreign objects, being jolted and
thrown off, and slipping and falling of the machine. Riders
also obstruct the operator’s view resulting in the tractor
being operated in an unsafe manner.
• Getting out of sticky situations safely
Attempting to free a stuck machine can involve safety
hazards such as the tow tractor tipping backwards and
overturning.The towchainortowbar can alsofailandrecoil
from its stretched condition causing injury and damage.
Back your tractor out if it gets bogged down in mud unhitch
any towed implements. Dig mud from behind the rear
wheels. Place boards behind the wheels to provide a solid
base and try to back out slowly. If necessary, dig mud from
the front of all wheels and drive slowly ahead.
If towing with another unit, use the tow bar and a long chain
(a cable is not recommended). Inspect the chain for aws.
Make sure all parts of the towing equipment are of adequate
size and strong enough to handle the load always hitch to
the drawbar of the towing unit. Do not hitch to the front
push bar attachment point. The hitch point should never be
above the rear drive axles.
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Safety Precautions
Before moving, clear the area of people. Apply power
smoothly to take up the slack. A sudden pull could snap any
towing equipment causing it to whip or recoil dangerously.
• Avoid high-pressure uids
Escaping uid under pressure can penetrate the skin
causing serious injury.
Avoidthehazardbyrelievingpressurebeforedisconnecting
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 uids.
If an accident occurs, see a doctor immediately. Any uid
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
medical source.
• Park tractor safely
To park tractor safely:
• Disengage the P.T.O..
• Lower the equipment to the ground.
• Put the gear shift lever into neutral.
• Apply the hand brake.
• STOP the engine.
• Remove the key.
Before you leave the operator’s seat, wait for the engine
and attachment parts to stop moving.
• Fuel and re safety
Handle fuel with care; it is highly ammable. Do not refuel
the machine while smoking or when near open ame or
sparks.
Always stop the engine before refueling the machine Fill
the fuel tank outdoors.
Prevent res by keeping the machine clean of accumulated
trash, grease, and debris. Always clean up spilled fuel.
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Safety Precautions
• Prepare for emergencies
Be prepared if a re starts.
Keep a rst aid kit and re extinguisher handy. Keep
emergency numbers for doctors, ambulance service,
hospital, and re department near your telephone.
• Do not use starting uid
DO NOT use starting uid to start DongFeng tractors.
• Wear protective clothing
Wear close tting clothing and safety equipment appropriate
to the job.
Prolonged exposure to loud noise can cause hearing
impairment or loss.
Wear a suitable hearing protective device such as
earmuffs or earplugs to protect against hearing loss from
uncomfortable loud noises.
Operating equipment safely requires the full attention of the
operator. Do not wear radio or music headphones while
operating the machine.
• Work in ventilated area
Engine exhaust fumes can cause sickness or death. If it is
necessary to run an engine in an enclosed area, remove
the exhaust fumes from the area with an exhaust pipe
extension.
If you do not have an exhaust pipe extension, open the
doors and ventilate the area with clean outside air.
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Safety Precautions
• Avoid contact with pesticides
Theenclosedcabdoesnotprotectagainstinhaling harmful
pesticides. Respiratory protection is required. If pesticide /
herbicides are used and respiratory protection is required,
wear an appropriate respirator inside the cab.
Within the cab, wear personal protective equipment as
required by the hazardous chemical safety instructions.
Remove protective equipment and store in a closed box or
some other type of sealable pesticide resistant container,
such as a plastic bag.
Clean your shoes or boots to remove soil or other
contaminated particles prior to entering the cab.
• Stay clear of rotating drivelines
Entanglement in rotating driveline can cause serious injury
or death.
Keep tractor master shield and driveline shields in place at
all times. Make sure rotating shields turn freely. Wear close
tting clothing. Stop the engine and be sure P.T.O. driveline
is stopped before making adjustments, connections, or
cleaning out P.T.O. driven equipment.
• Use safety lights and devices
Avoid collisions with other road users when using slow
moving tractors with attachments or towed equipment, and
self-propelled machines on public roads. Frequently check
for trafc from the rear, especially in turns, and use turn
indicators.
Use headlights, ashing warning lights, and turn indicators
day and night. Follow local regulations for equipment
lighting and marking. Keep lighting and marking visible,
clean, and in good working order.
Replace or repair lighting and marking that has been
damaged or lost. A safety lighting kit is available from your
DongFeng dealer.
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Safety Precautions
• Safety chains
A safety chain will help control towed equipment should it
accidentally separate from the drawbar.
Using the appropriate adapter parts, attach the chain to the
tractor drawbar support or other specied anchor location.
Provide only enough slack in the chain to permit turning.
See your DongFeng dealer for a chain with a strength
rating equal to or greater than the gross weight of the
towed machine.
Do not use safety chain for towing.
• Transport safety
A disabled tractor is best transported on a atbed carrier.
Use chains to secure the tractor to the carrier.
Never tow a tractor at a speed greater than 16 km/h
(10mph). An operator must steer and brake the tractor
under tow.
• Tow loads safely
Stopping distance increases with speed and weight of
towed loads, and on slopes. Towed loads with or without
brakes that are too heavy for the tractor or are towed too
fast can cause loss of control. Consider the total weight of
the equipment and its size.
Observe recommended maximum road speeds, or local
speed limits which may be lower:
• If towed equipment does not have brakes, do not travel
more than 20 km/hr and do not tow loads more than 1.5
times the tractor weight.
• If towed equipment has brakes, do not travel more than
30 km/hr 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
when towing loads under adverse surface conditions, when
turning, and on inclines.
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Safety Precautions
• Keep ROPS installed properly
Make certain all parts are reinstalled correctly if the roll-
over protective structure (ROPS) is loosened or removed
for any reason. Tighten mounting bolts to proper torque.
The protection offered by ROPS will be impaired if ROPS is
subjected to structural damage, is involved in an overturn
incident, or is in any way altered by welding, bending,
drilling, or cutting. A damaged ROPS should be replaced,
not reused.
• Practice safe maintenance
Understand service procedure before doing work. Keep
area clean and dry.
Never lubricate, service, or adjust machine while it is
moving.
Keep hands, feet, and clothing from power-driven parts.
Disengage all power and operate controls to relieve
pressure.
Lower equipment to the ground. Stop the engine. Remove
the key. Allow machine to cool.
Securely support any machine elements that must be
raised for service work.
Keep all parts in good condition and properly installed. Fix
damage immediately. Replace worn or broken parts.
Remove any buildup of grease, oil, or debris.
On self-propelled equipment, disconnect battery ground
Cable (-) before making adjustments on electrical systems
or welding on machine.
On towed implements, disconnect wiring harnesses from
tractor before servicing electrical system components or
welding on machine.
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Safety Precautions
• Service cooling system safely
Explosive release of uids from pressurized cooling system
can cause serious burns.
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 rst
stop to relieve pressure before removing completely.
• Service tractor safely
Do not service the tractor while it is in motion or while the
engine is running.
When servicing front-wheel-drive-equipped tractor with rear
wheels supported off ground and rotating wheels by engine
power, always support front wheels in a similar manner.
Engaging front-wheel drive will pull rear wheels off support
if front wheels are not raised.
Tighten wheel hardware to correct torque as specied
in Wheels, Tyres and Tread section. Torque at intervals
shown in Break-In Period and Lubrication and Maintenance
sections, to ensure that wheel hardware does not loosen.
Reinstall protective covers removed during service.
• Support machine properly
Always lower the attachment or implement to the ground
before you work on the machine. If you must work on a
lifted machine or attachment, securely support the machine
or attachment. If left in a raised position, hydraulically
supported devices can settle or leak down.
Do not support the machine on cinder blocks, hollow tiles,
or props that may crumble under continuous load. Do not
work under a machine that is supported solely by a jack.
Follow recommended procedures in this manual.
When implements or attachments are used with a tractor,
always follow safety precautions listed in the implement
operator’s manual.
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Safety Precautions
• Remove paint before welding or heating
Avoid potentially toxic fumes and dust.
Hazardous fumes can be generated when paint is heated
by welding, soldering, or using a torch.
Do all work outside or in a well ventilated area. Dispose of
paint and solvent properly.
Remove paint before welding or heating:
• lf you sand or grind paint, avoid breathing the dust. 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 ammable material from
area.Allow fumes to disperse at least 15 minutes before
welding or heating.
• Avoid heating near pressurized uid lines
Flammable spray can be generated by heating near
pressurized uid lines, resulting in severe burns to yourself
and bystanders.
Do not heat by welding, soldering, or using a torch near
pressurized uid lines or other ammable materials.
Pressurized lines can be accidentally cut when heat goes
beyond the Immediate ame area.
• Store attachments safely
Stored attachments such as dual wheels, cage wheels, and
loaders can fall and cause serious injury or death. Securely
store attachments and implements to prevent falling. Keep
playing children and bystanders away from storage area.
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