Mahindra YUVRAJ 215 Service Manual Download | Manualshive

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Summary of Contents for YUVRAJ 215

Page 1: ...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 Foreword Produc...

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Page 3: ...Index Description Page No General Specifications 05 Engine 07 Transmission 29 Hydraulics 45 Front Axle Steering 71...

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Page 5: ...em Water cooled pressurised Cap Operating Pressure 0 9 kg sqcm without thermostat Clutch Clutch Type 200 mm dry Single plate Crerametalic type Transmission Type Sliding Mesh No of Gears 6 Forward 3 Re...

Page 6: ...l Tank 25 Transmission Hydraulic System 15 Air Cleaner 0 5 Dimensions In mm Overall Height mm 1690 Overall Length mm 2440 Ground Clearance mm 260 Overall Width mm 1175 Wheel Base mm 1480 General Speci...

Page 7: ...ENGINE ENGINE ENGINE ENGINE ENGINE ENGINE ENGINE ENGINE ENGINE ENGINE ENGINE ENGINE ENGINE ENGINE ENGINE...

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Page 9: ...Cooling System Water cooled pressurised Cap Operating Pressure 0 9 kg sqcm without thermostat MANIFOLD CYLINDER HEAD VALVES Inlet Valve No of Inlet Valve 1 Stem Diameter mm 8 93 8 95 Port diameter mm...

Page 10: ...ses deg ATDC 25 3 CONNECTING RODS PISTONS AND CYLINDER SLEEVES Connecting Rod Material EN18 D Connecting Rod Big End Bearing Material Steel back p copper lead Connecting Rod Small End Bearing Type Bus...

Page 11: ...tom Groove mm 3 Ring Groove Clearance Top groove mm 0 137 Middle groove mm 0 08 0 04 Bottom groove mm 0 09 0 07 Piston Pin Inner Diameter mm 16 Outer Diameter mm 30 Clearance in piston mm 0 016 0 004...

Page 12: ...ve pinion to camshaft mm 0 08 Clearances Gears to housing mm 0 075 0 153 Drive shaft to body mm 0 037 to 0 074 Drive pinion to body end float mm 0 075 to 0 123 COOLING SYSTEM Type Water cool force fee...

Page 13: ...Replaceable shell Material Steel backed babbit Bi Metal WEAR LIMITS Cylinder sleeves Bore diameter mm 100 030 0 150 Ovality mm 0 06 Taper mm 0 06 Piston Rings Ring gap First ring mm 1 Second ring mm...

Page 14: ...5 Nm 8 Counter Unbalance shaft 40 to 50 Nm 9 Oil pump mtg bolt Hex bolt M8 x 35 8 8 25 to 30Nm 10 Hex Bolt M8 X 20 For oil pump gear and water pump rear mounting bolts 20 to 25Nm 11 Oil Pump spacer Ny...

Page 15: ...0 5 6 10 to 12 Nm 26 Exh And Air Intake manifold mtg stud M10X42X1 5 45 to 50 Nm 27 Exh manifold mtg bolt M 8 x 25 20 to 25 Nm 28 Breather pipe mtg stud M 6 x 30 5 8 10 to 12 Nm 29 Hex nut for Adjustm...

Page 16: ...25 Nm 44 M6 Banjo bolt for injector overflow pipe 5 to 7 Nm AIR FILTER EXHAUST SILENCER SUB ASSEMBLY 45 Exh Manifold manifold hex nut M10 45 to 50 Nm 46 Hex bolt for stub pipe mtg M8 x 30 8 8 25 to 30...

Page 17: ...10 to 12 Nm 60 Hex bolt for Flange for Outlet Hose M8 x 20 8 8 12 to 15 Nm ACCESSORIES SUB ASSEMBLY 62 Hyd pump mtg bkt Flange Headed Bolt M12 x 75 12 9 45 to 50 Nm 63 Hex bolt for hour meter adapter...

Page 18: ...by removing the radiator drain plug 4 Remove the brace plate of radiator 5 Remove the clip of radiator each inlet outlet hose 6 Remove the two nos radiator mounting spring loaded bolts plain washer an...

Page 19: ...n pipe below the transmission housing has to be removed by removing two bolts with the help of 7mm ratchet 12 Remove the four nos of hydraulic pump mtg bolts spanner size 12 13 remove the hydraulic pu...

Page 20: ...Remove the four nos of Phillips screws of scuttle front panel by the screwdriver remove it 18 Disconnect all wiring harness couplers connected to the scuttle 19 Remove the pull to stop knob 20 Remove...

Page 21: ...two bolts of fuel filter remove the fuel filter to pump pipe Remove the filter 27 Remove the radiator mounting bracket by removing the two nos bolts 16mm 28 Remove the four bolts M12 of front axle su...

Page 22: ...e 12mm alternator brace remove the brace 34 Remove the alternator by removing the bolt 35 Remove the two bolts of alternator bracket remove the bracket Spanner size 8mm 36 Remove the two bolts of brea...

Page 23: ...ips of the hose between the water pump and crankcase block 39 Remove the two bolts of water pump remove it Spanner size 13mm 40 Remove the hour meter adaptor by removing two bolts 41 Remove the three...

Page 24: ...over remove it 44 Remove the four bolts of the cylinder head Spanner Size 3 4 45 Remove the two nos bolts of rocker arm remove the rocker arm shaft Rail of rocker arm 46 Remove the rocker arm Push rod...

Page 25: ...bly 50 Remove the circlip of piston pin 51 Hammer the piston pin with a mallet and remove the piston pin piston Dismantling procedure of crankcase front cover 52 Remove the nine bolts of the front eng...

Page 26: ...he accelerator lever bracket 60 Remove the Accelerator lever bracket 61 Remove the three bolts to remove the fuel injection pump 13mm 62 Remove the fuel injection pump its gasket 63 Remove the camshaf...

Page 27: ...uller MST H1 EN on the Crankcase Screw the bolt such that the threaded portion fits into the spindle Tighten the lock nut such that the spindle is pulled out along with the bolt 68 Remove the pin of t...

Page 28: ...replaced in case of replacement required for gears 76 Remove the 12 nos bolts of the oil pan 77 Remove the oil pan 78 Remove the two bolts of the connecting rod cap remove the connecting rod cap 79 R...

Page 29: ...haft Main Bearing Retainer Puller Bolts Puller Bolts Crankshaft Thrust Washer Engine Before Assembly ensure that 1 Use new gaskets o rings Oil Seals and fasteners 2 All bearings must be cleaned lubric...

Page 30: ...on any of the two cylinder head studs and with the help of given spacers tighten the tool Torquen the nuts to 40 Nm This will ensure that the tapered portion of the Cylinder blocks sits properly in t...

Page 31: ...m 5 Clean housing from inside and place foam inside 6 Completely clean top and bottom filter element dry them with compressed air and put in to filter 7 Fill the oil bowl up to oil filling mark and as...

Page 32: ...Hi Idle Engine R P M Check Power Response Exhaust Smoke Check Air Cleaner Oil Bath Type Pre cleaner Clean Wire Mesh Bowl Clean Replace Oil Air Cleaner Connections Check Fuel System Fuel Filter First a...

Page 33: ...NSMIS TRANSMIS TRANSMIS TRANSMIS TRANSMISSION SION SION SION SION TRANSMIS TRANSMIS TRANSMIS TRANSMIS TRANSMISSION SION SION SION SION TRANSMIS TRANSMIS TRANSMIS TRANSMIS TRANSMISSION SION SION SION S...

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Page 35: ...dal Operated GEAR BOX Make M M Type Sliding Mesh Number of Gears 6 Forward 3 Reverse Gear Shift Pattern Gear Shift Lever Hi low Reverse Shift Lever Transmission Oil Including Hydraulic EP90 Capacity 1...

Page 36: ...Brake Hsg To Bull Cage 41 50 11 Clamping Plate to Transcase 21 25 12 Clutch ReleaseFork to Clutch Shaft 21 25 13 Washer Angular Contact Brg to Transcase 21 25 14 Nut For Bracket Spring Holding 21 25...

Page 37: ...jack or hoist Loosen the bolts of the tyre remove both the tyres Loosen the drain the plug of the transmission drain the transmission oil Remove the transmission breather dipstick for free flow of tr...

Page 38: ...e drive shaft may get bend 8 Remove the roll pins of transmission drive shaft with the help of roll pin punch remove the drive shaft 9 Remove the coupling by removing the roll pins with the help of ro...

Page 39: ...ar shift rail from the transmission 12 Remove the gear shift section shifter 13 Remove the rail holding the shifting forks by tapping it for the rear end Differential side Note The rail has spring bal...

Page 40: ...ar with the help of a mallet 7 With the help of circlip piler remove the circlip of PTO drive shaft bearing 8 Tap remove the bearing of PTO shaft drive shaft 9 Remove 3 nos of bolt spring lock washer...

Page 41: ...spanner remove the PTO shifter retaining shaft 20 Rotate remove the PTO shifter by tapping with the mallet from the outside 21 Remove the PTO shifter oil seal 22 Clean all the parts with the help of c...

Page 42: ...two discs take out the 4 nos of Steel balls e Remove the crank link of each actuating disc by removing the nut bolt 10 Remove the inner friction disc 11 Clean all the part with the help of cleaning f...

Page 43: ...help of 10 mm spanner LH Bevel cum Bull Shaft RH Bevel cum Bull Shaft Adaptor LH Bull Cage RH Bull Cage Crown Wheel 2 Tap remove the bull cage LH RH with the help of mallet Hold the differential cage...

Page 44: ...ion 4 Remove the 7 nos of bolts spring washer mounting the rear axle assembly to the transmission with the help of 10 mm spanner Place the assembly in a clean place 5 Tap the rear axle inner end with...

Page 45: ...Driving Shaft Assembly 1 Remove the 3 nos of bolts washer of Counter shaft retainer with the help of 8 no spanner 2 Remove the retainer with oil seal by tapping the retainer with mallet 3 Remove the...

Page 46: ...he housing 7 Hold the constant mesh gear with one hand with other pull the spline shaft till the constant mesh gear is free to come out of the transmission case remove the constant mesh gear with step...

Page 47: ...47 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 Transmission...

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Page 49: ...HYDRA HYDRA HYDRA HYDRA HYDRAULIC ULIC ULIC ULIC ULICS S S S S HYDRA HYDRA HYDRA HYDRA HYDRAULIC ULIC ULIC ULIC ULICS S S S S HYDRA HYDRA HYDRA HYDRA HYDRAULIC ULIC ULIC ULIC ULICS S S S S...

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Page 51: ...98 Bell Crank Bell Crank Pin mm 20 00 19 9 Sr No Description Torque Nm 1 Closure Plate to VTU Bolt 45 to 50 2 Mounting Bolts 18 to 20 3 Bell crank to DC Outer Rod Bolt 18 to 20 4 Quadrant Tightening B...

Page 52: ...osition Control Control set for Transporting 1 2 7 5 6 3 4 1 Lever Position Control 2 Lever Draft Control 3 Cam 4 Roller Arrangement of Position Control Linkages 5 PC Actuating Link 6 Spring 7 Spool 1...

Page 53: ...53 Schematic Layout Showing Details of Control Valve Components in Neutral Position Hy tec Hydraulics...

Page 54: ...eve Control Valve 18 Pilot Port Sleeve CV 19 Lifting Port Sleeve CV 20 Lowering Port Sleeve CV Sr No Description 21 Tank Port 22 Main Plug 23 Tank Port Bypass 24 Orifice 0 8 mm dia 25 Seat Check Valve...

Page 55: ...55 Lifting Position Hy tec Hydraulics...

Page 56: ...56 Lowering Position Hy tec Hydraulics...

Page 57: ...there will be no return to reservoir from the spool and the pressure either side of the restricting orifice will equalise As the two sides of the regulator piston 11 have different areas this pressure...

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Page 60: ...plement draft moves the link outer draft sensing 5 against the spring thus move the spool control valve plunger As the spool plunger moves inward The pilot port sleeve is uncovered the consequent pres...

Page 61: ...ement In this pressure way due to shock loads or many thousand and p s i may result As soon as these shocks exceed specified limits the cylinder cushion valve will become unseated relieving pressure i...

Page 62: ...ator spool has stuck in the fully opened position or the pump efficiency is low d Back Pressure With the draft control lever in the deepest position and the position control lever in the full lower po...

Page 63: ...ball ends to the ground Fully lower the lift arms then raise until the control lever is against the stop and on the same side of the stop as in the first test Measure the height of the ball ends from...

Page 64: ...upling pressure pipe or port 9 3 check valve is leaky remove check valve and observe sear for any damage observe O ring for any cut and deformation etc Before reassembling change O ring on seat h Afte...

Page 65: ...f DC Connecting link 4 Remove the M8 bolt of pin crank top link 5 Remove the pin crank top link 6 Remove crank top link 7 Remove 2 bolts M12 x 1 75 of draft sensing mounting assembly 8 Remove sleeve d...

Page 66: ...outer rocker 8 Remove the spacer of DC Outer rocker B Removal of Control Valve assembly 1 Remove the 8 bolts 1 2 UNC of the CV Assembly with spring washer 2 Remove the control valve Remove two small a...

Page 67: ...sh DC Feedback shaft 5 Remove bolt from cam of cable DC feedback 6 Remove DC rocker Allen Screw 7 Remove DC rocker assembly DC Outer Link Spacer Oil Seal Bush DC Inner Rocker Bush Bolt DC Feedback Cab...

Page 68: ...ssembly 10 Remove the PC roller assembly D Removal of Quadrant assembly 1 Remove two bolts of quadrant assembly Bolt Size M10 x 1 5 2 Remove quadrant assembly Allen Screw PC Roller Assembly Quadrant B...

Page 69: ...Remove spacer quadrant draft control 6 Remove the Quadrant spring 7 Remove the two bolts of quadrant strip Spanner Size15mm 8 Remove the quadrant strip DC slider Plate Retainer Bolts Spacer Quadrant...

Page 70: ...riction retainer 12 Remove friction disc 13 Remove PC lever assembly 5 Removal procedure of power train 1 Remove circlip of rockshaft RH 2 Remove lift arm RH Circlip DC Lever Assembly Friction Retaine...

Page 71: ...g and lifting to the top again with the position control lever It should now be possible to lift the links a further 12 5mm approximately by moving the draft control lever to the top most position b C...

Page 72: ...be drained strainer cleaned oil refilled as follows 1 Clean the area around the filter plug suction strainer orific filter 2 Remove drain plug then allow the oil to drain in to a suitable container re...

Page 73: ...eaking Valve or cylinder head O ring leaking Isolator valve leaky Spigot O ring leaky B Valve parts leaking due to wear a Main control valve damaged or worn surface b Check valve damaged ball surface...

Page 74: ...h pressure line Pipes vibrating Faulty pump Position of position control stop lever not correct Orifice filter choked Regulator piston stuck in closed position Isolator valve not fully closed Isolator...

Page 75: ...AXLE STEERING STEERING STEERING STEERING STEERING FRONT AXLE STEERING FRONT AXLE STEERING FRONT AXLE STEERING FRONT AXLE STEERING FRONT AXLE STEERING FRONT AXLE STEERING FRONT AXLE STEERING FRONT AXLE...

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Page 77: ...Front Wheel Mounting Bolts 110 11 Hood Bracket Mounting Bolts 60 12 PTO Cap Mounting Bolts 21 13 Hand Brake Mounting Bolts 21 14 Radiator Mounting Bolts 21 15 Hydraulic Filter Mounting Bolts 60 16 Sea...

Page 78: ...RH 11 Bolt M12 12 Wahser Spring Lock 13 Nut M12 14 Bush King Pin Sleeve 15 Washer Cast Iron 16 Seal Oil King Pin Sleeve 17 Knuckle Steering Cpte LH Sr No Description 18 Knuckle Steering Cpte RH 19 V S...

Page 79: ...Wheel hub 1 Remove the Front wheel by removing the 4 Wheel nuts 2 Remove the Front Wheel Cap which is press fitted 3 Remove the Split pin on the Castle nut and remove the Castle nut 4 Remove the wash...

Page 80: ...e b Steering knuckles b Check steering knuckle shafts binding and bushings for seizure or lack of lubrication c Work or damaged c Check drag link drop arm steering linkage steering knuckle arms for we...

Page 81: ...sing the puller 3 Remove the four bolts of the steering column 4 Remove the woodruff key on which the steering wheel is mounted 5 Remove the steering column tube Drop Arm Nut Drop Arm Steering Gear Dr...

Page 82: ...82 6 Remove the shims 7 Remove the spacer 8 Remove the bearing cage 9 Remove the nut over the adjusting screw Shims Spacer Cage Bearing Adjust Screw Steering Assembly...

Page 83: ...11 Adjusting screw need to rotate to take cover off 12 Remove the circlip 13 Remove the adjuster screw with plain washer 14 Remove the worm assembly 15 Remove the main steering column Steering Gear Co...

Page 84: ...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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