Assembly of Devonn 254G2 + 304G2 Tractors

Step 1:
 Uncrate tractor leaving bottom support in place
 Remove plastic from all parts ---- careful on paint

l
ia
 Locate bolt box (Big Red steel box)

Tr
Step 2:
 Install front weight and hood latch assembly – Square up and tighten very tight
Step 3:
3
 Attach hoist to front bar and pin in top hole of top link anchor

m
o !
co
e
ft.
ca t
a
ns
re
.s
C
w
w
w
F

- attach chain and hoist, lift tractor up so crate bottom is just

off the floor
PD

 Remove anchors from front and rear wheels, pull out bottom crate panel and lift tractor 2 feet in air (always
keep level as possible)
Step 4
 Drain oils
 2 rear drain plugs---2 - 20 liter pails Allow 1 hour to drain
 
 Drain engine oil – 1 - 20 liter pail Allow 1 hour to drain
 Drain oil in Injection pump – 1/3 liter

l
ia
Tr

Step 5
 Remove PTO cover plate and clean gasket surface
3
m
o !
co
e
ft.
ca t
a
ns
re
.s
C
w
w
w
F


 Leave PTO lever back DO NOT move into neutral
PD

 Install roller bearing into PTO gear deep inside tractor

 Careful install PTO assembly and tap in with soft hammer

 Lubricate o-ring on housing
 Install housing with seal by carefully tapping into place with soft hammer
 Install PTO shield and secure all with 4 bolts
  Install PTO cover and hand tighten
 Clean plug magnets on drain plugs and replace in tractor – do not over tighten
 Pour in oil Transmission/Rear end 22 liters ATF ( Red Oil)
 Pour motor oil in very slowly 6 Liters (HDX 10W30)
 Injection pump 1/3 liter (HDX 10W30)
 Drain power steering system by removing power steering hoses from cylinder,

l
ia
Tr
 Place a bucket under the cylinder, then push front wheels to the right, then left several times and turn steering
wheel left 2 turns and then right 2 turns - reattach hoses.
3
m
o !
co
e
ft.
ca t
a
ns
re
.s
C
w
w
w
F

 Install power steering tank

 Fill power steering tank with 1.5 liters ATF (Red Oil)
PD

Step 6
 Remove fuel filter assembly to gain access to frost plug to install block heater

 Remove frost plug by driving in on the bottom of the plug to rotate and use heal bar to remove plug
  Clean and smooth hole with emery cloth, remove sharp edge to allow oring to slide in easier
 Put grease on o-ring and hole in block and carefully install heater (Temro #3100010) guiding o-ring with
screwdriver while pressing in on heater

 Tighten screw in center of heater

 Fill cooling system with 10 liters 50/50 antifreeze


l
Check for leaks

ia
 Replace fuel filter assembly

Tr
Step 7
 Install front tires and tighten
 Install steering wheel-grease spline and thread
Step 8


3
Remove hydraulic control levers from valve and bend 3 inches forward and reinstall
Install Hydra control valve - make sure copper washers and the surfaces are CLEAN
m
o !
co
e
Step 9 IMPORTANT – Will not fit later
 Clean 3 PTH anchor pin hole, then oil and install pin – watch 1 side larger than other – install small end first
ft.
ca t

from Right hand side of tractor, watch pin holes…keep them vertical – tap with soft hammer
a
ns
re
.s
C
w
w
w
F
PD

Step 10
  Install roll bar side brackets and 3 PTH anchor brackets on each side…leave loose

l
ia
Tr
 Install fenders – Use 8 mm bolts on front lower fender mounts. Tighten after all bolts are in place
 Tighten fender bolts and roll bar anchor bolts
 Install wire through hole in roll bar and fender – use a wire hook to fish wire through
3
m
o !
co
e
ft.
ca t
a
ns
re
.s
C
w
w
w
F
PD

 Install side lights on roll bar

Step 11
 Put on rear wheels and tighten
 Lower tractor on to wheels
  Install top Roll Cage with 2 large bolts and rubber washers in-between

 Put pins in other hole on roll cage

l
ia
 Drill and tap bolt into front of roll cage (8x30mm) to eliminate noise from slack in pins

Tr
3
m
o !
co
e
ft.
ca t
a
ns

Step 12
re

 Remove fuel tank lid in order to get cover over spout

 Lift fuel tank into place and secure with 4 bolts
.s
C

 Put over flow line banjo fitting on tank

w

 Feed fuel supply line along side overflow line to injector pump and use clamp to secure – line is just long
w

enough
w
F

 Attached fuel gauge wire to sender – Black wire to side screw for ground
 Place 2 rubber bushing on top of each other by fuel tank for the cover
PD

 Lift tank cover over fuel spout and bolt down – top bolts must have large diameter washers and must not be
over tightened
  Replace fuel cap
 Put fuel into tank (20 liters)
 Pump hand pump until you can hear fuel returning to tank – bleed screw on top of filter may have to be
loosened – fuel will come out
Step 15
 Install drawbar assembly on the 4 bolts on rear of tractor – tighten

l
ia
Tr

3
m
Fit 3 PTH side arms and lift linkage
o !
 Sway bar in center hole – Eyebolt on outside – Arm - thick washer - lock washer and nut
co
e
 Lift link in next hole forward
ft.


ca t

Remove top link anchor 4 bolts and install top link storage bracket behind anchor - reinstall with same bolts
a
ns
re
.s
C
w
w
w
F
PD

Step 16
 Put LOCTITE on end threads of hood lift boosters and screw into ball joints on hood
 Lift and hold hood in place and attach boosters - up in the air
 Locate 4 -8mm bolts and secure rear of hood – Shims are required to align hood with dash – several tries may
be necessary
 Attach light wires and secure wire in brackets in hood
Step 17
  Remove clutch inspection cover on right side by brake pedals

l
ia
 Look for PTO clutch adjustment screws (3 of them - 120 degrees apart on flywheel)

Tr
3
m
o !
co
e
ft.
ca t
a

 Feeler gauge required and thickness of .060 in or 1.50 mm

ns

 Loosen lock nut and adjust to proper clearance - end of bolt to housing and retighten
re

 Check for release bearing touching all 3 fingers when free play is removed by pressing down clutch pedal
 They must all touch at the same time
.s
C

 Notice the gear shift mechanism above and behind the clutch – good idea to squirt a small amount of oil into
w

this mechanism while moving gearshift levers. - Not so much as to get into clutch
w

 Reinstall cover
w
F

Step 18
PD

 Undo lock nut on main shift lever and remove knob

 Unscrew 6 screws from dash
 Grease 1 clutch and 2 brake pedals zerks
 Remove 4 screws from bellows seal on dash
 l
ia
 Check 2 screws on gear lever – Tighten and oil mechanism
 Reverse bellows so to point inwards and reattach – shifting is much smoother

Tr
3
m
o !
co
e
ft.
ca t
a
ns
re

 Reinstall 6 screws
.s
C

Step 19
w

 Start engine – run at 1000 RPM for 5 minutes

w

 If engine is running a little rough at 1800 -2000 RPM the timing must be advanced 5 degrees
w
F
PD

 Put scribe mark on timing cover and on pump mount

 Loosen 3 screws on injection pump
 Twist pump on mount toward engine – watch to move only the thickness of your line
 Retighten pump – engine will run much smoother at higher RPM
 If everything is normal take tractor for a small drive, varying speeds and load…do not lug engine or rev high
(over 2000 RPM) for the first hour
 When engine is warmed up check the high RPM – Must be no more than 2400 RPM – Adjust injection pump
maximum speed screw to limit to 2400 RPM and reseal pump when finished
 If dynamometer is available engine should be run at least 2 hours before putting tractor on dyno
 Speed and load should be varied – never load for extended period at high RPM and maximum HP test should
be done for a very short period (2 minutes)
 254G2 with ZN390T engine @ 2200 RPM should produce 30-32 HP
 304G2 with ZN390T engine @ 2200 RPM should produce 35-36 HP

l
ia
Tr
3
m
o !
co
e
ft.
ca t
a
ns
re
.s
C
w
w
w
F
PD