Mahindra YUVRAJ 215 Service Manual
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Mahindra YUVRAJ 215 Service Manual

Mahindra YUVRAJ 215 Service Manual

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We are pleased to present the Service Manual for the "YUVRAJ 215" Tractor.
This Service Manual contains repair and maintenance information on Engine, Transmission,
Hydraulics and Other Aggregate of Tractor.
We hope this Service Manual will serve useful to you. For any further help or query contact
at the below mentioned address.
Product Support
Customer Care Department
Mahindra & Mahindra Ltd.,
Farm Equipment Sector,
Akurli Road,
Kandivli (E)
Mumbai - 400 101
PART NO: YUVR 215 SM01
Foreword

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Summary of Contents for Mahindra YUVRAJ 215

  • Page 1 Foreword We are pleased to present the Service Manual for the “YUVRAJ 215” Tractor. This Service Manual contains repair and maintenance information on Engine, Transmission, Hydraulics and Other Aggregate of Tractor. We hope this Service Manual will serve useful to you. For any further help or query contact at the below mentioned address.
  • Page 3 Index Description -------------------------------------------------------------- Page No General Specifications ----------------------------------------------------------------- 05 Engine --------------------------------------------------------------------------------------- 07 Transmission ------------------------------------------------------------------------------ 29 Hydraulics ---------------------------------------------------------------------------------- 45 Front Axle & Steering ------------------------------------------------------------------- 71...

  • Page 5: General Specifications

    General Specifications Engine Type FMW100 Water Cooled Direct Injection NA type Engine No. of Cylinders Bore / Stroke mm 100 / 110 Displacement cc 863.5 Rated Governed Speed 2300 ± 50 Low Idle R.P.M. 1050 ± 100 High Idle R.P.M. 2550 ±...
  • Page 6 General Specifications Tyre Size Rear 8 x 18 - 4pr Operating Weight & Distribution (Kgs) Front Rear Total Capacities (liters) Engine (including filter) 2.5 (1.5 ltr in Oil Pan & 1ltr in Crank Case) Cooling System (Approx) Steering Gear Box 0.33 Fuel Tank Transmission &...

  • Page 7: Engine

    ENGINE ENGINE ENGINE ENGINE ENGINE ENGINE ENGINE ENGINE ENGINE ENGINE ENGINE ENGINE ENGINE ENGINE ENGINE...
  • Page 9 Engine Specifications Engine Type FMW100 Water Cooled Direct Injection NA type Engine No. of Cylinders Bore / Stroke mm 100 / 110 Displacement cc 863.5 Rated Governed Speed 2300 + 50 Low Idle R.P.M. 1050 + 100 High Idle R.P.M. 2550 + 50 Valve Clearance Cold - Inlet - 0.1, Exhaust- 0.1, Hot - Inlet - 0.1,...
  • Page 10 Engine Specifications Valve Spring Free length (mm) 49.5+/-0.5 Spring rate@30-70%of finest Load (N/mm) 23.88 Valve Tappets (Cam Follower) Diameter (mm) Running Clearance (mm) 0.016 to 0.045 Valve Push Rods No of Push Rods Diameter (mm) Length (mm) 289.5+/-0.50 Valve Timing Inlet opens (deg.
  • Page 11 Engine Specifications Ring Gap Top (mm) 0.25 to 0.45 Middle (mm) 0.60 to 0.85 Bottom (mm) 0.35 to 0.55 Piston Type Re-entrant Material Aluminium Dia at crown 99.35 +/-0.015 Dia at skirt 99.88 Bumping Clearance 1.12 to 1.2 Number of Ring Groove (No.) Ring Groove Width (mm) Top Groove (mm) Middle Groove (mm)
  • Page 12 Engine Specifications LUBRICATION SYSTEM Pressure Requlating Valve Between the oil pump and oil filter Location Oil pump body In front lower side of crankcase Spring free length (mm) Opening pressure (kg/cm2) By-Pass Valve Location Filter Head "Extreme left on the Outer wall“ of crank case when viewed from Front of Engine"...
  • Page 13 Engine Specifications CRANKSHAFT Material Alloy steel EN 19 C Main journal diameter (mm) Running clearance main journal (mm) 0.028 / 0.153 Crank-pin diameter (mm) End clearance (float) (mm) 0.2 to 0.5 Running clearance crank pin (mm) 0.052- 0.098 Rear end oil seal dia. (mm) Main Bearings Type Replaceable, shell...
  • Page 14 Engine Torque Values TORQUE CHART FOR YUVRAJ 215 - FMW100 ENGINE DESCRIPTION & BOLT/NUT/STUD USED TORQUE-Nm CRANKCASE SUB-ASSEMBLY Fip.Mtg Stud to crank case(M8 x 22) 15 to 20 Nm Main brg housing mtg stud to crank case- ( M10 x 20) 25 to 30 Nm Camfollwer bkt Allen bolt (M10 x 48.5 - 12.9)
  • Page 15 TORQUE CHART FOR YUVRAJ 215 - FMW100 ENGINE DESCRIPTION & BOLT/NUT/STUD USED TORQUE-Nm CAM SHAFT,PUSH ROD,TIMING COVER SUB-ASSEMBLY High Idle seting Hex Nut (M8 - 8) 18 to 22 Nm Hex bolt for Timing cover (M 8 x 30 - 8.8) 25 to 30Nm Hex bolt for P.T.O.
  • Page 16 TORQUE CHART FOR YUVRAJ 215 - FMW100 ENGINE DESCRIPTION & BOLT/NUT/STUD USED TORQUE-Nm INJECTION EQUIPMENT SUB- ASSEMBLY Hex Nut for FIP (M8 - 8) 18 to 22 Nm Hex bolt for H.P.pipe clamp mtg (M8x16-8.8) 25 to 30 Nm Injector flange Hex Nut (M8 - 8) 25 to 30 Nm Fuel filter bkt Mrg bolt (M10 x 30 - 8.8)
  • Page 17 TORQUE CHART FOR YUVRAJ 215 - FMW100 ENGINE DESCRIPTION & BOLT/NUT/STUD USED TORQUE-Nm COOLING SYSTEM SUB-ASSEMBLY Hex bolt for water pumpmtg. Bkt.(Rear) (M8X20X8.8) 25 to 30 Nm Hex bolt for water pulley and spacer (IM6X35X-8.8) 10 to 12 Nm Hex bolt for Cooling fan and Spacer (M8 x 20-8.8)
  • Page 18 Engine Removal of Engine : Remove the clip of radiator each inlet & outlet hose. Dismantling of Bonnet & Radiator – Remove the two nos. nuts of bonnet of LH Hose Pipe & RH side. Hose Clip Bonnet Remove the two nos. radiator mounting spring loaded bolts &...

  • Page 19: Transmission

    Engine Remove the air cleaner by removing the 11 Remove the suction pipe. (Suction pipe two nos bolts of air cleaner assembly. below the transmission housing has to be removed by removing two bolts with the help of 7mm ratchet.) Cleaner Mounting Bolt...
  • Page 20 Engine 14 Remove the four nos bolts (13mm size) 17 Remove the four nos of Phillips screws of stub pipe on exhaust manifold & remove scuttle front panel by the screwdriver & the stub pipe with silencer assembly. remove it. Scuttle Pannel Front Stub Pipe...
  • Page 21 Engine 22 Remove the accelerator linkage. 23 Remove the three nos of bolts of steering mounting bracket (14mm- size) & remove Fuel Tank Fuel Tank the bracket. Mounting Bolt Steering Gear Box 27 Remove the radiator mounting bracket by removing the two nos bolts. (16mm). Mounting 28 Remove the four bolts (M12) of front axle Bolt...
  • Page 22 Engine 31 Remove the two nut of inlet manifold 34 Remove the alternator by removing the (Spanner size :17mm) & remove the bolt. manifold & gasket. Alternator Mounting Bolt Mounting Intake Manifold 32 Remove the two Nut of exhaust manifold 35 Remove the two bolts of alternator bracket (Spanner size 17mm) &...
  • Page 23 Engine 37 Remove the nut connected to the injector 39 Remove the two bolts of water pump & & other nut on the crankcase (17mm), to remove it. (Spanner size 13mm) remove the Fuel Pressure pipe loosen the clamp bolt. Injector Water Pump Mounting...
  • Page 24 Engine 42 Remove the crankshaft pulley by removing one bolt.( 16mm). Crankshaft Pulley Cylinder Head 45 Remove the two nos bolts of rocker arm & remove the rocker arm shaft. (Rail of rocker Dismantling procedure of the valve arm). housing cover & cylinder head Rocker 43 Remove the two bolts of the valve housing cover &...
  • Page 25 Engine 48 Valve Springs can be removed from the Dismantling procedure of crankcase front Cylinder head by removing the lock. cover- Remove the top retainer, Spring, Bottom 52 Remove the nine bolts of the front engine retainer and thrust washer. cover.
  • Page 26 Engine 57 Remove the clutch. 61 Remove the three bolts to remove the fuel injection pump (13mm). 58 Drain the oil from the oil pan. 59 Remove the nuts of the accelerator lever bracket. Fuel Injection Pump Accelerator 62 Remove the fuel injection pump & its Lever Bracket gasket.
  • Page 27 Engine 64 Remove the six nos Allen bolts (10mm) of threaded portion fits into the spindle. the flywheel assembly. Tighten the lock nut such that the spindle is pulled out along with the bolt. Flywheel Governor Mounting Spindle Allen Bolt Remover Special Tool 64 Remove the flywheel.
  • Page 28 Engine 71 Remove the crank gear with the help of 75 Remove the oil pump. puller (SST MST-H1-EN- ). Crank Gear Puller 72 Remove the ball hub & disc of the ball hub • The Oil Pump gears are non-serviceable. with the help of the puller.
  • Page 29 Engine 83 Remove the 6 nos bolts of the flywheel 86 Remove the crankshaft housing & remove the flywheel housing. Flywheel Crankshaft Housing 87 Remove the thrust washer. 84 Remove the 4 nos bolts of the rear retainer (17mm). Crankshaft Main Bearing Retainer Thrust...
  • Page 30 Engine The Crankshaft –gear has one dot on it which Value of X will always be greater then should be matched with matching marks (two 0.30mm. dots) on the camshaft gear. On the Crankshaft front end another gear is mounted with the help of key way . This gear is called as PTO gear which is having one dot.
  • Page 31 Engine Service Instruction for Air Cleaner Service 5. Clean housing from inside and place foam inside. 1. Remove oil bowl of air cleaner and drain entire oil. 6. Completely clean top and bottom filter element, dry them with compressed air and 2.
  • Page 32 MAINTENANCE CHART FOR ENGINE Activity To be done by Customer To be done by Dealer 10 Hrs Every Every Ev-ery Every / Daily 50 Hrs 250 Hrs 500 Hrs. 1000 Hrs. Engine ✔ ✔ ✔ ✔ ✔ ✔ ✔ ✔ ✔ ✔ ✔...
  • Page 33 TRANSMIS TRANSMIS SION SION TRANSMIS SION SION TRANSMIS TRANSMIS SION TRANSMIS TRANSMIS TRANSMIS SION SION SION SION TRANSMIS TRANSMIS TRANSMIS TRANSMIS SION SION SION TRANSMIS TRANSMIS SION TRANSMIS SION SION...

  • Page 35: Hydraulics

    Transmission Specification CLUTCH Make M & M Type Dry Organic Facing type No of Plate Single Plate Outer Diameter (mm) Thickness of Clutch plate (mm) Operating Method Pedal Operated GEAR BOX Make M & M Type Sliding Mesh Number of Gears 6 Forward &...
  • Page 36 Transmission Torque Charts Sr No Description Torque (Nm) Transcase Cover to Transcase 21 - 25 Retainer Layshaft to Transcase 21 - 25 Retainer Splineshaft to Transcase 21 - 25 Retainer Rear Axle to RAC 21 - 25 PTO Housing to Transcase 21 - 25 Bull Cageto Transcase 41 - 50...
  • Page 37 Transmission General : Remove the transmission breather / dipstick for free flow of transmission oil. To work or dismantle the transmission form engine, first remove the bellow aggregate or assemblies. 1. Fender assembly 2. Hydraulic assembly 3. Electrical system. 4. Linkage, pipes & fittings 5.
  • Page 38 Transmission 4. Remove the Clutch housing hand hole 9. Remove the coupling by removing the roll cover by removing 6 nos of bolts mounting pins with the help of roll pin punch. it on the clutch housing. 5. Remove the clutch release bearing shaft & Coupling fork as follows Roll...
  • Page 39 Transmission 6. Remove the Top cover of transmission case 13. Remove the rail holding the shifting forks by removing 10 nos of bolts with the help by tapping it for the rear end (Differential of spanner. side). Mounitng Bolt Transcase Cover Fork Rail 7.

  • Page 40: Front

    Transmission 3. Pull out the PTO shaft subassembly by 6. Remove the PTO drive shaft by tapping it holding the main PTO shaft. from the rear with the help of a mallet. PTO Drive Shaft 7. With the help of circlip piler remove the circlip of PTO drive shaft bearing.

  • Page 41: Rear

    Transmission 13. Remove the shims of PTO shaft. 18. Remove the roll pin of PTO shift lever with the help of roll pin punch & draw out the 14. Tap the main PTO shat with the help of PTO shift lever with ball & spring. mallet form the front side &...
  • Page 42 Transmission 3. Remove the breather. Dismantling of Reverse Idler Assembly 1. Remove the grub screw retaining the 4. Remove the cotter pin of the actuating disc reverse idler assembly on the transmission pull rod & remove the bolt of the pull rod. case with the help of 10 mm spanner.
  • Page 43 Transmission 7. Clean all the part with the help of cleaning 2. Tap & remove the bull cage LH & RH with fluid & inspect them for wear & damage, the help of mallet. Hold the differential replace if found worn & damage. cage assembly while removing the bull cage assembly LH &...
  • Page 44 Transmission 8. Remove the integral stud, inserted in the 2. Unlock the lock plate of bull gear locking bull shaft. nut & remove the lock nut with the spanner. Integral Stud 9. Dismantling of differential cage assembly. Lock a. Unlock the lock plate of bull cage cross shaft &...
  • Page 45 Transmission Dismantling of Counter Shaft Assembly Counter Shaft Retainer Counter (Driving Shaft Assembly) Shaft Hi-Low & Counter Shaft Reverse Cluster Retainer Bearing Gear Bearing 2nd & 3rd Driving Cluster Counter Gear Shaft Spacer Spacer Spacer 2nd & 3rd Driving Hi-Low & Reverse Cluster Gear Cluster Gear Bearing...
  • Page 46 Transmission 1. Remove the 3 nos bolts & spring lock 4. Unlock the lock plate of the Pinion shaft & washer with the help of 8 no. spanner. remove the bolt with lock plate & stopper plate of Pinion shaft. Mounting Bolt 2.
  • Page 47 Transmission For all above assemblies the assembly will be done in the reverse way of dismantling, although below important adjustment are to be carried out at the time of assembly step by step.
  • Page 49 HYDRA HYDRA ULIC ULIC S S S S S ULIC HYDRA ULIC HYDRA HYDRA ULIC HYDRA HYDRA ULIC ULIC ULIC S S S S S HYDRA HYDRA ULIC HYDRA HYDRA HYDRA HYDRA ULIC ULIC ULIC ULIC S S S S S ULIC HYDRA HYDRA...
  • Page 51 Hydraulic Specification & Torque Values Hydraulic Specifications The Pump Make Dowty Type Gear Capacity (cc/rev) 7.03 Output @ 2300 Engine RPM (lpm) Control Valve Make M & M Relief Valve Pressure (kg/sqcm) 123 - 157 Lift Cylinder (mm) 76.2 Rock Shaft Rockshaft OD (mm) 46.95 - 46.91 Bush ID (mm)
  • Page 52 Hydraulic Torque Values Arrangement of Position Control Linkages 1 Lever Position Control 5 PC Actuating Link 2 Lever Draft Control 6 Spring 3 Cam 7 Spool 4 Roller Arrangement of Draft Control Linkages 1 Lever Draft Control Sensing 2 Rocker Draft 6 Spring DC Rod Control 7 Cable...
  • Page 53 Hy-tec Hydraulics Schematic Layout Showing Details of Control Valve Components in Neutral Position...
  • Page 54 Hy-tec Hydraulics Sr. No Description Sr. No Description Pump Inlet Tank Port Spacer Compensator Main Plug Sleeve Compensator Tank Port Bypass Spool Compensator Orifice (0.8 mm dia) Spring Compensator Seat Check Valve Retainer Plug .Ball Check Valve Orifice Spring Check Valve Spring Regulator Valve Sleeve Check Valve II.
  • Page 55 Hy-tec Hydraulics Lifting Position...
  • Page 56 Hy-tec Hydraulics Lowering Position...
  • Page 57 Hy-tec Hydraulics General position there will be no return to reservoir from the spool and the pressure either side of the restricting orifice will equalise. As 1. Description the two sides of the regulator piston (11) These tractors are equipped with ‘Vary have different areas this pressure will have Touch’...
  • Page 60 Hy-tec Hydraulics actuating link pivots about PC roller assy spring thus move the spool control valve (2) and moves back towards rockshaft. This plunger. allows spool (10) to come out under the As the spool plunger moves inward. The action of spring main valve (38). This allow pilot port sleeve is uncovered, the the oil to return from lift cylinder and consequent pressure drop allow the...
  • Page 61 Hy-tec Hydraulics the top link force the top link spring (19) g. Remote Cylinder (20) will deflect. This displacement is To operate, single-acting cylinders, the passed to link outer draft sensing (5). The adjustable stop is moved to contact the movement of link outer draft sensing is upper limit stop, the position lever is then transfered to spool control valve (22) with...
  • Page 62 Hy-tec Hydraulics Maximum permissible pressure (Hydraulic With the control lever in “Lower” there lift element) 207 bar. should be no more than 0.127mm drop of the lower link ends in 30 seconds. Repair or replace the pump if capacity is WARNING : less than 75% of normal value.
  • Page 63 Hy-tec Hydraulics Pressure Testing the Valve Unit Before Assembling to the Housing a. Clean the control valve with help of air & make it dry. b. Remove external jack tapping plug. Fit special tool MST-H1/2-HD-12 & MST-H1/2- HD-11 Main Spool Valve Bore Relief Valve Bore Plug Connecting Check Valve to Control Valve Plug Connecting Cylinder to Control Valve...
  • Page 64 Hy-tec Hydraulics Raise the pressure to 125-140 kg/cm . Do not raise the pressure sufficiently to blow the relief valve. Wait for 2-3 minutes and observe plugs and ports for leakage. If any of these plugs are leaky tighten it or replace if required.
  • Page 65 Hy-tec Hydraulics Dismantling procedure of the hydraulics.- Remove the M8 bolt of pin crank top link. Remove the pin crank top link. A) Dismantling procedure of the bell crank Assembly- Remove the M14 lock nut of the crank toplink assembly. Pin Crank Toplink Crank Toplink...
  • Page 66 Hy-tec Hydraulic Remove outer DC sensing spring. B) Removal of Control Valve assembly. 10 Remove inner DC sensing spring. Remove the 8 bolts (1/2” UNC) of the CV Assembly with spring washer. 11 Remove Spindle Draft Sensing.. Control Valve 12 Remove sensing bottom sleeve. 13 Remove external circlip of the DC feedback link &...
  • Page 67 Hy-tec Hydraulic Remove the clevis pin. DC Outer Link Bush DC Inner Seal Clevis Pin Rocker Clevis Spacer Remove bolt from cam of cable DC feedback. Remove the DC inner rocker assembly. Bolt DC DC Inner Feedback Rocker Cable Remove DC rocker Allen Screw. Remove Bush DC Feedback shaft.
  • Page 68 Hy-tec Hydraulic Remove Allen Screw of PC rocker. Removal of Quadrant assembly. Remove two bolts of quadrant assembly (Bolt Size M10 x 1.5) Allen Screw Quadrant Remove the PC link assembly. Bolts PC Rocker Assembly Remove quadrant assembly. 10 Remove the PC roller assembly. Quadrant Assembly PC Roller...
  • Page 69 Hy-tec Hydraulics Remove the two bolts (M10 x 60) of plate Remove the Quadrant spring. spring retainer. Quadrant Spring Plate Retainer Bolts Remove plate spring retainer. Remove the two bolts of quadrant strip. (Spanner Size15mm) Bolts Bolts Spacer Quadrant Quadrant Remove spacer quadrant draft control.
  • Page 70 Hy-tec Hydraulic Remove the circlip from PC tube. 12 Remove friction disc. 13 Remove PC lever assembly. Circlip Remove Circlip PC Lever Tube Removal procedure of power train Remove DC lever Assembly. Remove circlip of rockshaft (RH) DC Lever Assembly Lift Arm Rocker Shaft...
  • Page 71 Hy-tec Hydraulics Remove LH side circlip of rockshaft ADJUSTMENTS Remove locking bolt of cam rocker arm. a. Adjusting the Position Control (13mm) Connect the lower links to a dead weight of 450kg. Open the isolating valve and set the draft lever to the deepest position.
  • Page 72 Hy-tec Hydraulic Clean the area around the filler/level plug before removing the plug. Add oil of specified grade up to the slotted mark given on dipstick whenever required. b. Replacement of suction filter Replace the suction filter after every 250 hrs.
  • Page 73 Hy-tec Hydraulic T R O U B L E S H O O T I N G TROUBLE PROBABLE CAUSE REMEDY Fill to correct level Hitch lifts slowly Oil level in reservoir is low (Not lifting with full speed) Replace or repair the Pump Fall in pump efficiency Clean strainer! replace filter Suction strainer! Suction line filter...
  • Page 74 Hy-tec Hydraulic TROUBLE SHOOTING TROUBLE PROBABLE CAUSE REMEDY Noisy System Low oil level Fill to correct level Clogged suction strainer Remove and clean Air in the system Check oil level and suction line joints Load movement restricted Check for free movement of the links and that load is not fouling tractor Restriction in high pressure...
  • Page 75 FRONT AXLE & FRONT AXLE & FRONT AXLE & FRONT AXLE & FRONT AXLE & FRONT AXLE & STEERING FRONT AXLE & STEERING FRONT AXLE & STEERING FRONT AXLE & STEERING FRONT AXLE & STEERING FRONT AXLE & STEERING FRONT AXLE & STEERING FRONT AXLE &...
  • Page 77 Front Axle & Support Torque Values Sr No Description Torque (Nm) Front Wheel Nut 65 to 75 Rear Wheel Nut 180 to 200 Drag link & Tie Rod Nut 35 to 40 Steering Arm Nut 110 to 120 Front Axle Support Mounting Bolts Pivot Pin Mounting Bolt Enine Mounting Bolts to Clutch Housing (Shorter Length)
  • Page 78 Front Axle & Support 24 23 22 19 28 26 Sr. No. Description Sr. No. Description Support Front Axle Knuckle Steering Cpte RH Axle Front Complete V Seal Front Wheel Hub washer Thrust Front Axle Support 4.5 Dust Shield ‘O’ Ring Pivot Pin Sleeve Seal Oil Front Wheel Hub Bush Pivot Pin Sleeve Spacer Inner Bearing...
  • Page 79 Front Axle & Support General Removal of Steering Arm & Steering Knuckle : The Single Piece Front Axle are of box section steel construction. The axle Pivots on a Pin 1) Remove the locking bolt of the Knuckle arm, which passes through the Front Axle Support holding the Knuckle arm with the Steering and is retained in position by Lock Plate secured knuckle.
  • Page 80 Front Axle & Support TROUBLE SHOOTING TROUBLE PROBABLE CAUSE REMEDY (1) Tractor will not steer. Work or damaged Check drag link, steering steering linkage, knuckle arms and drop arm for wear or damage. Faulty steering gear assembly. (2) Tractor is hard to steer. Low tyre pressure.
  • Page 81 Steering Assembly Remove the four bolts of the steering Dismantling procedure of steering gear column. Remove the nut of the drop arm. (Spanner Size 34) Drop Arm Drop Arm Steering Column Nut Remove the woodruff key on which the Remove the drop arm by using the puller. steering wheel is mounted.
  • Page 82 Steering Assembly Remove the shims. Remove the bearing cage. Shims Cage Bearing Remove the spacer. Remove the nut over the adjusting screw. Spacer Adjust Screw...
  • Page 83 Steering Assembly 10 Remove the four bolts on the end cover & 13 Remove the adjuster screw with plain remove the end cover. (Adjusting screw washer. need to rotate to take cover off.) Adjuster Mounitng Screw Bolt Steering Gear Cover 14 Remove the worm assembly.
  • Page 84 Steering Assembly 16 Remove the bottom bearing. Cage Bearing 17 Clean all the parts with cleaning and inspect all the parts for wear & damage. Replace defective and worn out parts with new ones. Note: Assembly of all parts will be in the reverse part of dismantling.

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