Mahindra Jivo 245 DI Service Manual
  1. Manuals
  2. Brands
  3. Mahindra Manuals
  4. Tractor
  5. Jivo 245 DI
  6. Service manual

Mahindra Jivo 245 DI Service Manual

Hide thumbs
Table of Contents

Advertisement

Quick Links

SERVICE MANUAL

Advertisement

Table of Contents
loading

Related Manuals for Mahindra Jivo 245 DI

Summary of Contents for Mahindra Jivo 245 DI

  • Page 1 SERVICE MANUAL...

  • Page 2: Table Of Contents

    INDEX Sr. No. Description Page No. GENERAL Product Specification Safety Notes MAINTENANCE Maintenance Chart Special Service Tools List Special Service Tools Details Engine Transmission 12-13 4 WD Front Axle 14-15 Fault Tracing Greasing Point Location Consumable Details Primary Check Up Bleeding Fuel System Tyre Maintenance Front Wheel Toe - In...
  • Page 3 INDEX Sr. No. Description Page No. TRANSMISSION Transmission Torque Values Bearing and Oil Seal Positions Transmission Oil & Greassing Locations Transmission Slidingmesh Gears And Shafts Layout 45-46 Speed Bottom Shaft Mounting Speed Housing Fork & Rail Mounting Speed Shifter Assembly & Mounting 49-50 Speed Driving Shaft Mounting Cluster Gear Mounting...
  • Page 4 GENERAL...

  • Page 5: Product Specification

    PRODUCT SPECIFICATION MAHINDRA JIVO 245DI ENGINE Type Mahindra - MDI 1365 NX24 No. of Cylinders Engine Power 20 H.P. & 24 H.P. Bore 88.9 Stroke Displacement CC 1366 Rated Governed Speed 2300 ± 50 Low Idle R.P.M. 900 ± 50 High Idle R.P.M.

  • Page 6: Product Specification

    PRODUCT SPECIFICATION GENERAL...
  • Page 7 PRODUCT SPECIFICATION SAFETY - ALERT SYMBOL AND TERMS Why is SAFETY important to you? ACCIDENTS DISABLE AND KILL ACCIDENTS ARE COSTLY ACCIDENTS CAN BE AVOIDED This Safety Alert Symbol means ATTENTION! BE ALERT! YOUR SAFETY IS INVOLVED! The safety alert symbol identifies important safety messages on machines, safety signs, in manuals, or elsewhere.
  • Page 8 MAINTENANCE...
  • Page 9 Check & rectify      Engine Oil Level Check      Oil (API CH4/SAE 15W40/ Mahindra M-Star) Change     Oil Filter Change     Valve Clearance (Tappet Setting) Check ...
  • Page 10 API CH4 / SAE 15W40 / Engine Oil Mahindra M star Genuine Oil Every Service 23 (OIB + PS), 19 (Dry EP 90 (Dry Brake) / Mahindra Transmission Oil Brake Mech. Steering) M Star Transmission oil (OIB) 850 Hrs Front Axle 4WD...
  • Page 11 SPECIAL SERVICE TOOL DETAILS AGENYNH0061 AGENYNH0054 Protective sleeve for flywheel hous- ing insertion in crank shaft. It is essential to use protective Dolly for flywheel housing oil seal pressing- sleeve to avoid Use of this dolly will ensure proper fitment damage of seal of seal in housing and will avoid repeat seal while assy.
  • Page 12 SPECIAL SERVICE TOOL DETAILS AGTNYNH0092 PROCEDURE TO USE TOOL Use tool to tighten lock nut on Spiral Bevel Shaft with torque wrench. Torque value-: (80-90) Nm AGTNYNH0101 PROCEDURE TO USE TOOL Hammer seal with the help of dolly Place the oil seal on the dolly AGTRYNH0016 PROCEDURE TO USE TOOL Place oil seal...
  • Page 13 SPECIAL SERVICE TOOL DETAILS AGTNYNH0038 PROCEDURE TO USE TOOL Place seal Input Shaft Retainer. Then using tool A G T N Y N H 0 0 3 8 ham- press seal AGTNYNH0013 AGTNYNH0069 Gauge for checking CCD between bevel pin- Dolly for oil seal pressing in PTO housing plate ion and diff.
  • Page 14 SPECIAL SERVICE TOOL DETAILS AGFAYNH0001 AGFAYNH0053 Dolly for pressing slinger in side housing Dolly for pressing slinger and bearing in housing PROCEDURE TO USE TOOL AGFAYNH0037 Place slinger on dolly & assemble bearing on Tool  for Spiral Pinion shaft crimping nut PROCEDURE TO USE TOOL PROCEDURE TO USE TOOL Use tool to tighten lock nut on Spiral Bevel ...
  • Page 15 SPECIAL SERVICE TOOL DETAILS AGFAYNH001 PROCEDURE TO USE TOOL Place oil seal in beam housing and press Dolly for pressing oil seal in beam housing with tool AGFAYNH0034 PROCEDURE TO USE TOOL Insert Dolly AGFAYNH0034 with sub assembly of oil seal and bearing inside Swivel Housing Assemble bearing and oil seal on dolly...

  • Page 16: Fault Tracing

    Check & fill oil to correct level. Hydraulic lock valve closed Open valve. Hydraulic pump has lost its efficiency Get the pump replaced. See Mahindra Tractor Dealer / Authorized Service Control valve defective Centre, See Mahindra Tractor Dealer / Authorized Service Control linkage defective...

  • Page 17: Greasing Point Location

    GREASING POINTS LOCATIONS Sr. No Location Greasing Points Front & Rear Pillow Block 4WD King Pin Spindle Clutch Pedal & Brake Pedal Range Shifter lever Bell Crank Assembly PTO Lever Clutch Shaft & Clutch Release Bearing Sleeve Tie Rod (Mech. + PS Steering) & Steering Knuckle Arm MAINTENANCE...

  • Page 18: Consumable Details

    Specs. Oil Grade- Oil Grade- Oil Grade- API CH4 / SAE 15W40 / EP-90 (Dry Brakes)/ SAE80W90GL5 Mahindra M star Mahindra M-Star Oil Genuine Oil (OIB) Fuel Filter Changed- Oil Quantity- 1st at 350 Hrs. 23 Ltr (OIB + PS), 19 Ltr Oil Quantity- 5.0 Liters Oil Quantity- 4.0 Liters...

  • Page 19: Primary Check Up

    Check to see that the oil level lies between the two marks. • Add oil only when the oil level reaches the lowest mark.Recommended oil -“Mahindra M-Star Genuine Engine Oil / API CH-4 SAE 15W40 Oil ⚠...

  • Page 20: Bleeding Fuel System

    BLEEDING FUEL SYSTEM Air must be removed : 1) When the fuel filter or lines are removed. 2) When water is drained from fuel filter. 3) When tank is completely empty. 4) When tractor is not used for a long period of time PROCEDURE OF BLEEDING AIR FROM FUEL SYSTEM Pump the fuel pump knob located on the top...

  • Page 21: Tyre Maintenance

    TYRE MAINTENANCE Checking tyre pressure For normal load and operation of the tractor the following tyre pressure is recommended Front tyre Rear tyres 6 x 14” 8.3 x 24” For field 1.3 kg/cm² 1.2 kg/cm² For road 2.0 kg/cm² 1.4 kg/cm² Note : 1.

  • Page 22: Front Wheel Toe - In

    FRONT WHEEL “ TOE IN ” Front Axle - Front Wheel “Toe-in” Check In the event of the tie rod setting being interfered with, then it is necessary to adjust the TOE-IN. Before measuring and adjusting the TOE-IN, ensure the front wheels are in the straight ahead position and the front axle is not tilted.

  • Page 23: Front Wiring Harness Layout

    FRONT WIRING HARNESS LAYOUT MAINTENANCE...

  • Page 24: Rear Wiring Harness Layout

    REAR WIRING HARNESS LAYOUT MAINTENANCE...
  • Page 25 FRONT AXLE ASSEMBLY...

  • Page 26: Wd Front Axle -Torque Values

    4WD FRONT AXLE -TORQUE VALUES BEARING & OIL SEAL POSITION 4WD FRONT AXLE ASSEMBLY...

  • Page 27: Maintenance Schedule On 4Wd Front Axle

    MAINTENANCE SCHEDULE ON 4WD FRONT AXLE Routine Service Schedule Mahindra 4x4 1100 1350 CHECK POINTS Hours Hours Hours Hours Hours Hours TRANSMISSION Check Oil Level and Top-up if ✔ ✔ ✔ ✔ ✔ ✔ necessary ✔ Change Oil First at 1100 hours & thereafter every 1000 hours...

  • Page 28: Wd Front Axle –Oil & Grease Specifications

    4WD FRONT AXLE –OIL & GREASE SPECIFICATIONS MAINTENANCE...
  • Page 29 SWIVEL & SIDE HOUSING SUB ASSEMBLY PART NUMBER. REF. DESCRIPTION OF PART QTY. 000012506P04 BOLT Hex M12X30 10.9GR WASHER Spring M12 005550700R1 SPINDLE Front Axle 006513294Y1 BOLT HEXFL M10X1.5X25.5X8.8 000020313E05 008003896B1 SEAL Cassete 48X75X17 006513300Y1 HOUSING Hub 006517151Y1 SHMS 66X70X0.5 006517154Y1 SHIM 46X50X0.1 006517153Y1...
  • Page 30 SWIVEL & SIDE HOUSING SUB ASSEMBLY PART NUMBER. REF. DESCRIPTION OF PART QTY. SHIM 54X60X0.2 006514364Y1 SHIM 54X60X0.1 006514363Y1 006513298Y1 HOUSING Swivel LH 000020286E05 WASHER Sealing 26X36 006516642Y1 PLUG DRAIN Align Type GREASE NIPPLE M6 007602043C1 BOLT Flanged Hex. Head M12X1.5X35 000016469P04 ARM Knuckle LH (MS) 006515092Y1...
  • Page 31 HUB END -ASSEMBLY PROCESS Assemble the Cas- sette Seal (5) with Assemble the final hub Housing (6) Reduction bevel gear (10) to Spin- with the help of dle Front axle (3) suitable special purpose dolly. Assemble A s s e m b l e Bearing 35X72X17 Bearing (8) in Hub Hous-...
  • Page 32 HUB END -ASSEMBLY PROCESS HUB END ASSEMBLY CRITICAL SETTINGS On hub housing, measure the GAP from bearing top to hub housing flange using tool “AGFAYNMG 004” For Example- Master height = 35.00 mm Measured reading = - 0.204 mm GAP = 35.000 – 0.204 = 34.796 mm SWIVEL HOUSING SUB ASSEMBLY Assemble Ball...
  • Page 33 SWIVEL HOUSING SUB ASSEMBLY SWIVEL HOUSING SUB ASSEMBLY CRITICAL SETTINGS On Swivel housing, measure the GAP from bearing resting face to Swivel housing flange using tool “AGFAYNMG 003” For Example- Master height = 35.00 mm Measured reading = - 0.208 mm GAP = 35.000 + 0.204 = 35.208 mm SIDE HOUSING SUB ASSEMBLY LH &...
  • Page 34 SWIVEL TO SIDE HOUSING ASSEMBLY Insert clined shaft (33) Assemble into swivel hous- side housing assembly. assembly in Hub Housing Insert the Shim assembly (14) Swiv- Housing Insert the final re- Fitment of cir- duction shims (13) clip (34) on side between Swivel housing...

  • Page 35: Differential Assembly

    SWIVEL TO SIDE HOUSING ASSEMBLY SWIVEL TO SIDE HOUSING ASSEMBLY CRITICAL SETTINGS 1)When Swivel housing & Hub housing is assembled together there will be a gap. Recommended GAP is 0.200 mm. Hence SHIM ‘14’ will be required. GAP= Measured Gap- Recommended Gap 2) Assemble Hub housing on Swivel housing with some End Reduction Shims.

  • Page 36: Spline Shaft Assembly

    SWIVEL TO SIDE HOUSING ASSEMBLY DIFFERENTIAL ASSEMBLY CRITICAL SETTINGS 1) Measure the gap between circlip & bearing. Gap should be 0.10 mm (maximum). Add SHIM (differential assembly axial float) to adjust the extra gap. 2) Measure the backlash between Crown Wheel & Pinion with a dial gauge.
  • Page 37 SPLINE SHAFT ASSEMBLY LAYOUT PART NUMBER. REF. DESCRIPTION OF PART QTY. 006513358Y1 NUT Lock M30X1.5 006513358Y1 SPACER Oil Seal Mounting 006506912B1 OIL SEAL Retainer Rear Axle 006507407D1 CIRCLIP INT - LUG 62 006514373Y1 SHIM 58X62X0.1 006514295Y1 SPACER 58X62X4.5 006514294Y1 SPACER 58X62X4.0 006513391Y1 SPACER End 006513342Y1...

  • Page 38: Spline Shaft Assembly

    SPLINE SHAFT ASSEMBLY LAYOUT SPLINE SHAFT ASSEMBLY CRITICAL SETTINGS CONE CENTER DISTANCE As per the value etched on Pinion & bearing height SHIM = CONSTANT – (value etched on pinion face + value to measure) Use special tool for measuring bearing height (bearing outer race top to inner race top) PINION BEARING PRELOAD...

  • Page 39: Beam Housing Assembly

    BEAM HOUSING ASSEMBLY Take diff case (17) & insert bevel gear RH (B) & LH (A) with thrust washers (C). Insert bevel pinion (12) with Pinion Thrust Washers (13) in Apply sealant side hous- differential case & dock complete assembly to the beam housing (For LH &...

  • Page 40: Beam Housing Assembly

    BEAM HOUSING ASSEMBLY Mount Front pillow Block after mounting the 1 Mount Rear pillow Block after mounting the 2 no of O Ring no of O Ring Mount Knuckle arm sub LH & RH on swivel Mount Grease nipple of Front & Rear pillow Housing Apply Torque 21-25 NM Apply Torque 100-124 NM...

  • Page 41: Critical Setting On 4Wd Front Axle Chart

    CRITICAL SETTING ON 4WD FRONT AXLE CHART CRITICAL SETTING Stopper bolt adjustment LH & RH side housing should be (60+1/-1) mm LIST OF CRITICAL SETTINGS FOR 4WD FRONT AXLE Cone Centre Distance As per the number etched on Pinion Pinion Preload 3.0 –...
  • Page 42 TRANSMISSION...

  • Page 43: Transmission Torque Values

    TRANSMISSION - TORQUE VALUES BEARING & OIL SEAL POSITIONS TRANSMISSION MAIN LINE ASSEMBLY...
  • Page 44 TRANSMISSION OIL AND GREASE SPECIFICATIONS TRANSMISSION MAIN LINE ASSEMBLY...

  • Page 45: Transmission Slidingmesh Gears And Shafts Layout

    TRANSMISSION SLIDINGMESH GEARS AND SHAFTS LAYOUT PART NUMBER. REF. DESCRIPTION OF PART QTY. SHAFT Spiral Bevel 10T ‡ E006504606D1 BEARING Tapper Roller Bevel Pinion Shaft (35x62x18.25) 006505768D1 SHIM Laysyhaft 0.5mM 006505770D1 SHIM Laysyhaft 0.05mm 006505769D1 SHIM Laysyhaft 0.2mm 006513093Y1 SPACER Bevel Pinion Shaft TRB 0703DD4120N BEARING TRB MD GEAR 30207 J2 Q 006512422Y1...

  • Page 46: Transmission Slidingmesh Gears And Shafts Layout

    TRANSMISSION SLIDINGMESH GEARS AND SHAFTS LAYOUT PART NUMBER. REF. DESCRIPTION OF PART QTY. 006505619D1 NRB Spline SHAFT Pilot 006512417Y1 SHAFT Counter With Cm Gear Driver (16T) 006507467B1 BALL BEARING 6206 000012230P04 CIRCLIP EXT - LUG 30 X 2 006512420Y1 GEAR Cluster 3RD (31T) And 4TH(25T) Driven 006512419Y1 GEAR 2ND Driven 006505861B1...

  • Page 47: Speed Bottom Shaft Mounting

    SPEED BOTTOM SHAFT MOUNTING Fit 1st driven gear Press Ball bearing with NRB with on counter shaft application of (22) And mount oil & place front 1st & 2nd circlip spacer on count- er shaft on shaft after ⚠ NOTE- Ensure bearing with 90 free rotation of...

  • Page 48: Speed Housing Fork & Rail Mounting

    SPEED HOUSING FORK & RAIL MOUNTING Insert the 2nd rail on fork and as- semble the grub screw. A p p l y T o r q u e 2 0 - 2 5 N m A s s e m b l e lock Locate the shifter block (A) on 1st &...

  • Page 49: Speed Shifter Assembly & Mounting

    SPEED SHIFTER ASSEMBLY & MOUNTING A s s e m b l e Insert Circlip outer internal Link with straight shaft circlip plier. speed shift- Insert Coni- ing (S) lock- ing it with cal spring (S). roll pin (R) Insert ⚠...

  • Page 50: Speed Shifter Assembly & Mounting

    SPEED SHIFTER ASSEMBLY & MOUNTING REF. DESCRIPTION OF PART QTY. REF. DESCRIPTION OF PART QTY. PART NUMBER. PART NUMBER. SCREW Pan Head m4x10 SPACER Stopper-Spring 000012904P04 006512276V1 KNOB Speed Lever LIP SEAL Rotary Shaft 007544530Y1 006511675V1 LEVER Speed Shifting SHAFT Cross Gate Speed Shifting 006513780Y1 006512465Y1 CLIP-Hose Warm Drive...

  • Page 51: Speed Driving Shaft Mounting

    SPEED DRIVING SHAFT MOUNTING Press the ball bearing 6205-1Z & Fit the Circlip on driving shaft by using 90O Bend plier Circlip on driving shaft using Bend plier & Insert shims as per measured value Press the bush In Shim = Gap Between 4th Gear and bear- shaft at rear end ing 6206.

  • Page 52: Cluster Gear Mounting

    CLUSTER GEAR MOUNTING Insert spacer on driving shaft. Fitment of CM driven gear on cluster shaft with ⚠ NOTE- Ensure orientation of spacer as snap rings one before and after of the gear shown only Insert NRB in range cluster gear & fit this cluster gear assy on driving shaft Press bearing 6305 on the speed driving shaft NOTE- Ensure free rotation of NRB...

  • Page 53: Speed Housing And Clutch Housing Assembly

    SPEED HOUSING AND CLUTCH HOUSING ASSEMBLY Press Ball bearing on counter shaft (22) And mount Insert clutch shaft 1st & 2nd circlip through fork hole, washer & C clamp on shaft after on clutch housing bearing with 90 Deg. Bend Plier Dock clutch housing to speed housing applying sealant...

  • Page 54: Rear Axle Carrier Assembly & Mounting Process

    REAR AXLE CARRIER ASSEMBLY & MOUNTING PROCESS QTY. QTY. PART NUMBER. REF. PART NUMBER. REF. DESCRIPTION OF PART DESCRIPTION OF PART BOLT Ring Gear Differential 006513400Y1 GEAR Bull LH 006508412U1 Case BEARING Rear Axle Inner 006512987Y1 LOCK PLATE Bull Gear 006513004Y1 CARRIER Rear Axle RH 006512985Y1...

  • Page 55: Rear Axle Carrier Assembly & Mounting Process

    REAR AXLE CARRIER ASSEMBLY & MOUNTING PROCESS Insert shims Insert Rear Axle (A) and fix lock assembly washer (C) along with roll Rear axle casing (B) & lock plate assembly (D) in bull gear Mount axle Dock (LH + RH) RAC to Rear hous- mounting bolt (1) on bull gear with...

  • Page 56: Bevel Pinion Shaft Sub Assembly

    BEVEL PINION SHAFT SUB ASSEMBLY Press outer taper Press inner TRB roller bearing in spiral bev- retainer passing it through bev- el pinion shaft el pinion shaft Insert spacer and Lock the spline press shims of shaft bearing cage required thick- set up by using ness as per cal-...

  • Page 57: Bullcage & Differential Assembly

    BULLCAGE & DIFFERENTIAL ASSEMBLY PART NUMBER. REF. DESCRIPTION OF PART QTY. PART NUMBER. REF. DESCRIPTION OF PART QTY. 006512981Y1 CAGE Bull Dry LH 006512432Y1 PINION Differential 006514438Y1 CAGE Bull OIB LH 006512477Y1 WASHER Thrust Differential Pinion OIL SEAL Drive Shaft Pto WASHER Thrust Bevel Gear Side 005558067R91 006512478Y1...
  • Page 58 DIFFERENTIAL CASE ASSEMBLY & DIFFERENTIAL LOCK MOUNTING Take diff case (17) Press & insert bevel bearing (7) on gear RH (B) & LH LH & RH side of diff case with (A) with thrust pressing dolly washers (C). Insert bevel Insert Diff pinion (12) with...
  • Page 59 DIFFERENTIAL CASE ASSEMBLY & DIFFERENTIAL LOCK MOUNTING BEVEL PINION SHAFT AND DIFFERENCIAL CASE CRITICAL SETTINGS CCD- CONE CENTER DISTANCE Once the ‘Spiral Pinion Bearing preload’ & ‘Crown Bearing preload’ is done, assemble the ‘Spiral Pinion shaft’ sub-assembly in the rear housing with some shim Torque the ‘Spiral Pinion shaft’...

  • Page 60: Brake Assembly Mounting

    BRAKE ASSEMBLY MOUNTING Assemble the brake assembly(Rh) & (Lh ) on RH side and Lh side resp. with 6 no. of bolts on each side applying sealant 912. Apply Torque (41-55) NM on bolts with torque wrench to fix brake assembly on rear housing Assemble the breathers on brakes in proper direction &...

  • Page 61: Dropbox Assembly & Mounting On Rear Housing

    DROPBOX ASSEMBLY & MOUNTING ON REAR HOUSING Press location Insert shifting arm sleeve (S)in op- (S) in dropbox posite holes lock it with sub dropbox assembly of chock shown in image. Fit drain plug (D) block in drop box with shifting bracket applying...

  • Page 62: Speed Housing And Clutch Housing Mounting With Rear Housing

    SPEED HOUSING AND CLUTCH HOUSING MOUNTING WITH REAR HOUSING PART NUMBER. REF. DESCRIPTION OF PART QTY. PART NUMBER. REF. DESCRIPTION OF PART QTY. BOLT Flange Headed Hex RETAINER Lay Shaft With 007206788C1 M10X1.5X28 006512411Y1 First Gear Driving 006017521V1 PLUG Welch Dia 30.0 PLUG Drain Magnetic Met- 005556606R1 lok Precoate...

  • Page 63: Speed Shifter Assembly & Mounting

    SPEED SHIFTER ASSEMBLY & MOUNTING Assemble outer Insert Circlip in- cam Link (C) and ternal (C) with shaft speed shift- straight circlip ing (S) locking it plier. Insert Con- with roll pin (R) ical spring (S). Insert Cir- ⚠ NOTE- Ensure clip Internal free rotation of...

  • Page 64: Speed Pto Shaft And Gears Assembly And Mounting

    1 SPEED PTO SHAFT AND GEARS ASSEMBLY AND MOUNTING Take diff case (17) & insert bevel gear RH (B) & LH (A) with thrust washers (C). Insert shifting cou- pling driving shaft end. Insert bevel Insert the PTO output Shims (S) in rear pinion (12) with housing to adjust gap between driven &...

  • Page 65: Speed Pto Operating Linkage Mounting

    1 SPEED PTO OPERATING LINKAGE MOUNTING Insert the PTO cam assembly (C) Lock out- from inner side er cam(C) with of the transmis- shifter sion case. Adjust cam by means position as pin of roll pin (R) pto cam is in con- tact with coupling Press the oil seal (O) on the PTO...
  • Page 66 RANGE SHIFTER ASSEMBLY PART NUMBER. REF. QTY. DESCRIPTION OF PART 000012935P04 6 YOKE Lock Pin 7 LINK Connecting M10 006516656Y1 000012645P04 8 NUT HEX FL M10X1.25X9.8X8 007600229D1 9 YOKE Standard RH M10x1.25 006513137Y91 10 PIVOT Range Cross Shaft 000020308E05 11 BOLT For Oil Pan M8X1.0X16 000016322P04 12 LOCK PLATE 006510797V1 13 WASHER Diff Lock...

  • Page 67: Range Shifter Assembly & Mounting

    RANGE SHIFTER ASSEMBLY & MOUNTING Press the oil seal (O) on cross shaft. Lock the cross Lock Range cam shaft with Wash- link outer (C) to cross shaft us- (W), lock ing Roll pin (R) plate (L) & bolt (B) with Torque ( 2 0 - 2 7 ) N m RANGE SHIFTER ASSEMBLY CRITICAL SETTINGS Maintain Range Shifter lever length to 122 mm...

  • Page 68: Transmission Covers Mounting

    REVERSE IDLER SHAFT ASSEMBLY AND MOUNTING Assemble Reverse NOTE:- Ensure oil application on NRB Assembly idler assy ⚠ should be free from dust and foreign (R) on housing particles Lock it with bolt No grease application. (G) & washer (W) Cut portion of shaft should face upward to Rear Housing Lock plate should be hammered on lock...

  • Page 69: Engine

    ENGINE...

  • Page 70: Detailed Engine Specifications

    DETAILED ENGINE SPECIFICATIONS ENGINE ASSEMBLY...

  • Page 71: Engine Torque Chart

    ENGINE TORQUE CHART Torque PART DESCRIPTON (Nm) BOLT assembling Crankcase to flywheel housing 120-125 BOLT mounting oil pan to crankcase 24-30 BOLT mounting oil pan to front cover 35-40 BOLT mounting FC to crank case 24-30 BOLT mounting Brace to water pump stud 35-40 BANJO BOLT conecting hose to feed pump 10-14...
  • Page 72 ENGINE TORQUE CHART Assembly Part Torque Part Name Remarks Stage Number Values PRECOATED PLUG M13 X 1.5 X 8 006017519V1 15-20 MOG Plug PLUG M10 X 1.0 HEX SOCKET PIPE 000020786E05 11-14 COG plug OIL PRESSURE SWITCH 000013085P05 15-20 HEX HEAD PLUG M12 X 1.5 X 18 TAPER 006022117Y1 20-25 Water Drain plug...
  • Page 73 ENGINE TORQUE CHART Assembly Part Torque Part Name Remarks Stage Number Values Wat er pump NUT HEX M10 X 1.5 X 8 X 8 000022055RD 35-40 Assy Crank pulley BOLT HEXFL M14X1.5X50X10.9 006505679D1 175-185 For mounting Crank pulley to Crank Shaft Assy 37 Flywheel Hsg BOLT M12 x 1.75 x 40L X10.9 FLANGED...

  • Page 74: Engine Torque Chart

    ENGINE TORQUE CHART Assembly Part Torque Part Name Remarks Stage Number Values Pre 40-45 Flywheel As- BOLT HEX M12 X 1.5 X 40 X 10.9 006017528V1 Final For Mounitng Flywheel to Crank Shaft sembly 90-95 BOLT BANJO M14X1.5X26 001232932R1 30-35 Fuel filter pipe outlet connection Fuel Filter Assy FLANGED BOLT M10X25...

  • Page 75: Recommended Fip Removal Instruction

    RECOMMENDED FIP REMOVAL INSTRUCTION ⚠ CAUTION:- FIP MAY GET DAMAGED IF NOT FOLLOWED THE FIP REMOVAL INSTRUCTION Pull to stop Hole on screws. housing Line on flywheel Pull to stop lever 1. Remove starter motor. 3. Remove fuel line and HPP pipes from FIP 2.

  • Page 76: Recommended Fip Mounting Instruction

    RECOMMENDED FIP MOUNTING INSTRUCTION Slot on control 1. Make sure to match line on flywheel to hole on flywheel rack rod housing 2. Make sure FIP mounting studs and dowel are properly torqued in crankcase, 3. Place selected shim assembly (based on the crank case punch mark) on crankcase face making sure all dowels and mounting studs are matched to shim holes.

  • Page 77: Tappet Settings

    CYLINDER HEAD BOLT TORQUE Cylinder head mounting bolts torque sequence should be followed sequentially & in two stages. a. Tighten all bolts (Bolt no. 1 to 8) sequentially as shown, with 60 Nm torque then apply 90 degree angular torque. b.
  • Page 78 TAPPET SETTINGS 21. Do tappet setting of 1st cylinder. 14. Loose nut, tighten grub screw & insert filler 22. Insert filler gauge of 0.30 mm for Inlet valve gauge. 23. Loose nut, tighten grub screw & insert filler 15. Tighten the nut by keeping filler gauge in insert position.

  • Page 79: Engine Trouble Shooting

    ENGINE TROUBLE SHOOTING SR. NO. TROUBLE PROBABLE CAUSE REMEDY 1. Battery too low to turn engine. Charge battery or install new one. Inspect for faulty cables and terminals. 2. Starting switch inoperative Replace s arting switch if necessary Refer to Service Manual “Electrical 3.
  • Page 80 ENGINE TROUBLE SHOOTING SR. NO. TROUBLE PROBABLE CAUSE REMEDY 9. Loose or broken connections or leaking gaskets at intake manifold or Tighten or repair. exhaust manifold Reset as necessary. If out of 10. Improper valve settings adjustment an excessive amount, check for bent push rods.
  • Page 81 ENGINE TROUBLE SHOOTING SR. NO. TROUBLE PROBABLE CAUSE REMEDY 9. Piston ring sealing defective. Replace if required. Drain fuel from tank and fill 10. Improper fuel in tank. with new fuel. Check tank fuel level and clean 11. Fuel Tank vent blocked. tank cap for blocked vent 12.
  • Page 82 ENGINE TROUBLE SHOOTING SR. NO. TROUBLE PROBABLE CAUSE REMEDY 9. Sticking valves or bent valves Free stem and correct cause. Poor stems Replace valves with bent stems. Compression 10. Faulty valve action Adjust valve clearance. Vent air from water pump 1.
  • Page 83 ENGINE TROUBLE SHOOTING SR. NO. TROUBLE PROBABLE CAUSE REMEDY Engine Check the tension; replace, 25. Fan Belt Roll Slippage Overheats if greasy or worn. Remove and clean air cleaner and 1. Insufficient air to engine air cleaner pipe. 2. Defective injection nozzles Replace with serviceable unit.
  • Page 84 ENGINE TROUBLE SHOOTING SR. NO. TROUBLE PROBABLE CAUSE REMEDY 18. Air leak between intake Tighten or correct the joints. Excessive Oil manifold and engine. Consumption 19. Foreign object in exhaust (Contd.) Remove and clean. manifold. Test Nozzle and repair and reset 1.
  • Page 85 ENGINE TROUBLE SHOOTING SR. NO. TROUBLE PROBABLE CAUSE REMEDY 4. Loose bearings Install new bearings. Use grade of oil specified in 5. Use of improper lubricating operator’s manual. Use clean oil containers when filling engine with oil and see that 6.
  • Page 86 ENGINE TROUBLE SHOOTING SR. NO. TROUBLE PROBABLE CAUSE REMEDY Noisy Engine & 5. Rockers loose or out of adjustment Adjust tappet. Black 6. Valve clearance not OK Adjust tappet. Smoke 1. Defective fuel pump Rectify the fuel pump. Engine speed 2.

  • Page 87: Engine Trouble Shooting

    ENGINE TROUBLE SHOOTING SR. NO. TROUBLE PROBABLE CAUSE REMEDY 3. Thin or diluted oil Change oil 4. Bent push rods Install new push rods 5. Worn rocker arm Replace the rocker arms 6. Worn valve guides Replace valve guides 7. Valve clearance not OK. Adjust clearance.

Table of Contents