Mahindra YUVRAJ 215 Service Manual

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.

Product Support
Customer Care Department

Mahindra & Mahindra Ltd.,

Farm Equipment Sector,
Akurli Road,
Kandivli (E)
Mumbai - 400 101

PART NO: YUVR 215 SM01

Index

Description-------------------------------------------------------------- Page No

General Specifications ----------------------------------------------------------------- 05

Engine --------------------------------------------------------------------------------------- 07

Transmission ------------------------------------------------------------------------------ 29

Hydraulics ---------------------------------------------------------------------------------- 45

Front Axle & Steering------------------------------------------------------------------- 71

General Specifications

Engine

Type FMW100 Water Cooled Direct Injection

NA type Engine
No. of Cylinders 1
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,

Exhaust - 0.1
Air Cleaner Wire Mesh & Foam type Oil Bath
Nozzle Opening Pressure 247 to 261 kg/sqcm (250 + 8 bar)
Cooling System 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 Reverse with Hi-low-Reverse

Selector Lever
Power Take Off Rear mounted six splines, constant running - 450

R.P.M
Standard PTO rpm at rated engine speed 6 05
Brakes Totally enclosed self energising dry disc with

heavy duty friction linings

Hydraulic

Type Hytech Hydraulics. Fully live Hydraulic with

Position & Draft Controls
Lifting Capacity (Kgs) 450

Tractor

Steering Type Worm & Roller
Tyre Size Front 5.2 x 14 - 8pr

5

General Specifications

Tyre Size Rear 8 x 18 - 4pr

Operating Weight & Distribution (Kgs)

Front 340
Rear 51 0
Total 850

Capacities (liters)

Engine (including filter) 2.5 (1.5 ltr in Oil Pan & 1ltr in Crank Case)
Cooling System (Approx) 3.8
Steering Gear Box 0.33
Fuel Tank 25
Transmission & Hydraulic System 1 5
Air Cleaner 0.5

Dimensions (In mm)

Overall Height (mm) 1690
Overall Length (mm) 2440
Ground Clearance (mm) 26 0
Overall Width (mm) 1175
Wheel Base (mm) 1480

Overall Height

Ground

Clearance

Overall Length

Wheel Base

Overall Width

***Complying to Bharat (T erm) Stage III Emission norms
(All dimensions and specifications for guidance only & are subject to change without prior notice)

6

ENGINEENGINE

ENGINE

ENGINEENGINE

ENGINEENGINE

ENGINE

ENGINEENGINE

ENGINEENGINE

ENGINE

ENGINEENGINE

Engine Specifications

Engine

Type FMW100 Water Cooled Direct Injection

NA type Engine
No. of Cylinders 1
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,

Exhaust - 0.1
Air Cleaner Wire Mesh & Foam type Oil Bath
Nozzle Injection Pressure 247 to 261 kg/sqcm (250 + 8 bar)
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) 40 x 47
Clearance in guide,mm 0.05 to 0.08mm

Exhaust Valve

No of Exhaust Valve 1
Stem Diameter (mm) 8.93 / 8.95
Port diameter (mm) 32 x 38
Clearance in guide,mm 0.05 to 0.08mm
Tappet clearance Hot (mm) 0. 1
Tappet clearance Cold (mm) 0.1

Valve Guides

No of Guides 2
Length Inlet & Exhaust (mm) 5 6
Inside diameter (mm) 9
Set Height of guide measured from 42

cylinder head Topdeck
Height Inlet & Exhaust (mm) 56

+ 0.1

9

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) 12
Running Clearance (mm) 0.016 to 0.045

Valve Push Rods

No of Push Rods 2
Diameter (mm) 10
Length (mm) 289.5+/-0.50

Valve Timing

Inlet opens (deg. BTDC) 9 ± 3
Inlet closes (deg. ABDC) 48 ± 3
Exhaust opens (deg. BBDC) 52 ± 3
Exhaust closes (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 Bush
Material Steel back, 'Y' copper lead.
Small end bush diameter (mm) 30 +0.02/+0.033

Pistion Rings

Number of Rings per Piston 3
Top Ring Material Half Key stone, crome plated
Middle Ring Material Bevelled
Bottom Ring Material (Oil Ring) Chromepelated conformable Oil ring.

Ring Width (Axial)

Top (mm) 2.563
Middle (mm) 2
Bottom (mm) 3

10

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.) 3

Ring Groove Width (mm)

Top Groove (mm) 2.7
Middle Groove (mm) 2
Bottom 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) 1 6
Outer Diameter (mm) 3 0
Clearance in piston (mm) 0.016/0.004
Clearance in con rod (mm) 0.434/0.268
Length (mm) 7 8

Cylinder Sleeve

Type Non Replaceable wet liner
Material Synthetic Low alloy gray cast iron
Wall thickness (mm) 8.5
Sleeve I.D. (mm) 1 00
Max. taper (mm) 0.015
Max. ovality (mm) 0.01
Sleave I.D. Discard limit (mm) 100.030 + 0.150

11

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) 1 5
Opening pressure (kg/cm2) 3

By-Pass Valve

Location Filter Head "Extreme left on the Outer wall“ of crank case
when viewed from Front of Engine"

Opening pressure (kg/cm2) 0.8 to 1 bar

OIL PUMP INTERNAL ROTOR CAMSHAFT DRIVERS

Backlash (mm) 0.05 to 0.08
Drive 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 feed
Water Pump Type Centrifugal

TIMING GEAR TRAIN, FRONT COVER AND CAMSHAFT
Camshaft

Material EN -8
Number of bearings (No.) 2
Bearing Diameter Front (mm) 3 5
Bearing Diameter Rear (mm) 2 5
Running clearance (mm) 0.39 / 0.93
Exhaust cam lift (mm) 9
Inlet cam lift (mm) 8. 9
Max cam shaft lobe 3 0

Timing Gears

Number of teeth 40
Crankshaft gear (No.) 1
Camshaft gear (No.) 1
Backlash between any pair of gear (mm) 0.08

12

Engine Specifications

CRANKSHAFT

Material Alloy steel EN 19 C
Main journal diameter (mm) 6 6
Running clearance main journal (mm) 0.028 / 0.153
Crank-pin diameter (mm) 5 3
End clearance (float) (mm) 0.2 to 0.5
Running clearance crank pin (mm) 0.052- 0.098
Rear end oil seal dia. (mm) 6 4
Main Bearings
Type 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) 2
Third ring (mm) 2
Valve train
Valve guide clearance (mm) 0.05
Tappet valve clearance (mm) 0.3
Spring rate N/mm (Kg/mm) 16 (1.63)
Crankshaft
Main bearing clearance (mm) 0.18
End play (mm) 0. 8
Connecting rod
Big end bearing clearance (mm) 0.15
End play (mm) 0. 8

13

Engine Torque Values

TORQUE CHART FOR YUVRAJ 215 - FMW100 ENGINE

SR. DESCRIPTION & BOLT/NUT/STUD USED TORQUE-Nm
NO.

CRANKCASE SUB-ASSEMBLY

1 Fip.Mtg Stud to crank case(M8 x 22) 15 to 20 Nm
2 Main brg housing mtg stud to crank case- ( M10 x 20) 25 to 30 Nm
3 Camfollwer bkt Allen bolt (M10 x 48.5 - 12.9) 55 to 60Nm
4 Stud for Cyhead at rocker side 45 to 50 Nm
5 Stud for Cyhead at injector side 46 to 50 Nm
6 Engine flange mtg bolt (M 12 x 30) 65 to 70 Nm
7 Oil sump mtg bolt (M8 x16 - 8.8) 20 to 25 Nm
8 Counter Unbalance shaft 40 to 50 Nm
9 Oil pump mtg bolt (Hex bolt - M8 x 35 – 8.8) 25 to 30Nm
1 0 Hex Bolt M8 X 20 For oil pump gear and water pump

rear mounting bolts 20 to 25Nm
1 1 Oil Pump spacer Nylock nut 25 to 30Nm
1 2 Allen screw for Oil filter mtg bkt (M8 x 30 - 10.9) 25 to 30Nm
1 3 Hex bolt for low idle setting (M6 x 55 x 55 - 8.8) 10 to 12Nm
1 3 Hex bolt for Pull to stop lever bkt (M6 x 12-8.8) 10 to 12 Nm
1 4 Hex Socket Pipe Plug (M10X1) 15 to 18 Nm
1 5 Relief Valve Assembly 25 to 30 Nm

CRANKSHAFT, FLYWHEEL SUB -ASSEMBLY

1 6 Main brg housing Hex Nut ( M10 - 8) 45 to 55 Nm
1 7 Allen screw for flywheel (M12 x 75 - 12.9) 100 to 120 Nm
1 8 Allen screw for Balance weight (M10 x 50-10.9) 65 to 70 Nm

14

TORQUE CHART FOR YUVRAJ 215 - FMW100 ENGINE

SR. DESCRIPTION & BOLT/NUT/STUD USED TORQUE-Nm
NO.

CAM SHAFT,PUSH ROD,TIMING COVER SUB-ASSEMBLY

1 9 High Idle seting Hex Nut (M8 - 8) 18 to 22 Nm
2 0 Hex bolt for Timing cover (M 8 x 30 - 8.8) 25 to 30Nm
2 1 Hex bolt for P.T.O. shaft (M 10 x 45 - 8.8) 48 to 52 Nm

PISTON,CON. ROD SUB -ASSEMBLY

2 2 Con Rod bolt (M10 x 48 - 12.9) 60 TO 65 Nm
2 3 Stud for water inlet flange (M8 x 22 ) 12 to 15 Nm.
2 4 Hex bolt for closed flang of water inlet (M8 x 12-8.8) 20 to 25 Nm

CYLINDER HEAD SUB-ASSEMBLY

2 5 Injector flange stud (M 8 x 40 - 5.6) 10 to 12 Nm
2 6 Exh. And Air Intake manifold mtg. stud (M10X42X1.5) 45 to 50 Nm
2 7 Exh.manifold mtg bolt (M 8 x 25) 20 to 25 Nm
2 8 Breather pipe mtg stud (M 6 x 30 - 5.8) 10 to 12 Nm
2 9 Hex nut for Adjustment screw of rocker (M8) 18 to 22Nm
3 0 Hex bolt for Rocker shaft locking (M6 x 16-8.80 10 to 12 Nm
3 1 Hex Nut for cy.head (M12) 127 to 147 Nm
3 2 Rocker cover hex bolt (M8 x 50-8.8) 25 to 30 Nm
3 3 Rocker cover hex bolt (M8 x 75-8.8) 25 to 30 Nm
3 4 Hex nut for breather pipe (M 6 – 8.8) 10 to 12 Nm
3 5 Water Temperature Sensor 25 to30 Nm
3 6 Oil Pressure Switch 15 to 20 Nm

15

TORQUE CHART FOR YUVRAJ 215 - FMW100 ENGINE

SR. DESCRIPTION & BOLT/NUT/STUD USED TORQUE-Nm
NO.

INJECTION EQUIPMENT SUB- ASSEMBLY

3 7 Hex Nut for FIP (M8 - 8) 18 to 22 Nm
3 8 Hex bolt for H.P.pipe clamp mtg (M8x16-8.8) 25 to 30 Nm
3 9 Injector flange Hex Nut (M8 - 8) 25 to 30 Nm
4 0 Fuel filter bkt Mrg bolt (M10 x 30 - 8.8) 45 to 50Nm
4 1 Hex Nut for fuel filter mtg bolt (M10 - 8) 45 to 50 Nm
4 2 Fuel filter mtg bolt (M10 x 30 - 8.8) 45 to 50 Nm
4 3 Banjo Bolt M14 for fuel filter 20 to 25 Nm
4 4 M6 Banjo bolt for injector overflow pipe 5 to 7 Nm

AIR FILTER, EXHAUST SILENCER SUB-ASSEMBLY

4 5 Exh. Manifold manifold hex nut (M10) 45 to 50 Nm
4 6 Hex bolt for stub pipe mtg (M8 x 30-8.8) 25 to 30 Nm
4 7 Hex nut for stub mtg bolt (M8 – 8.8) 25 to 30 Nm
4 8 Hex nut for silencer clamp (M8 – 8.8) 25 to 30 Nm
4 9 Air cleaner manifold hex nut (M10 – 8.8) 45 to 50 Nm

STARTER MOTOR, ALTERNATOR SUB-AS SEMBLY

5 0 Hex bolt for starter mtg (M10 x 30 - 8.8) 45 to 50 Nm
5 1 Hex bolt for Alternator mtg bkt (M8 x 20 - 8.8) 25 to 30 Nm
5 2 Hex bolt for Alternator mtg (M8 x 110 - 8.8) 25 to 30 Nm
5 3 Hex bolt for Radial bkt (M 8 x 25 - 8.8) 25 to 30 Nm
5 4 Nut for Alternator Adj bolt (M8) 25 to 30 Nm

16

TORQUE CHART FOR YUVRAJ 215 - FMW100 ENGINE

SR. DESCRIPTION & BOLT/NUT/STUD USED TORQUE-Nm
NO.

COOLING SYSTEM SUB-ASSEMBLY

5 5 Hex bolt for water pumpmtg. Bkt.(Rear) (M8X20X8.8) 25 to 30 Nm
5 6 Hex bolt for water pulley and spacer (IM6X35X-8.8) 10 to 12 Nm
5 7 Hex bolt for Cooling fan and Spacer (M8 x 20-8.8) 25 to 30 Nm
5 8 Hex nut for Flange for Inlet Hose (M8 - 8) 12 to 15 Nm.
5 9 Hex bolt for Fan spacer (M6X30) 10 to 12 Nm
6 0 Hex bolt for Flange for Outlet Hose (M8 x 20-8.8) 12 to 15 Nm.

ACCESSORIES SUB-AS SEMBLY

6 2 Hyd pump mtg bkt Flange Headed Bolt(M12 x 75 - 12.9) 45 to 50 Nm
6 3 Hex bolt for hour meter adapter (M6X16X8.8) 10 to 12 Nm
6 4 Hex bolt for hour meter (M8 x 16 - 8.8) 25 to 30 Nm
6 5 Plug Magnetic Drain ( Oil Pan Drain Plug ) 40 to 50 Nm
6 6 Oil Filter 15 to 20 Nm
6 7 Fuel Injection Pump M12 Banjo bolt 20 to 25 N.m
6 8 Fuel Injection Pump M8 banjo bolt and fuel return

line M8 banjo bolt 6 to 10 N.m
6 9 Tappet Bolt for Crankshaft Pulley 45 to 50 Nm
7 0 HPP Nut M12 at FIP and M14 at Injector End 20 to 25 N.m

17

Engine

Removal of Engine :

Dismantling of Bonnet & Radiator –

1 Remove the two nos. nuts of bonnet of LH

& RH side.

Bonnet

Nut

2 Remove the two nos bolts of bonnet. &

remove the Bonnet.

5 Remove the clip of radiator each inlet &

outlet hose.

Hose

Pipe

Hose

Clip

6 Remove the two nos. radiator mounting

spring loaded bolts & plain washer and
remove the radiator.

3 Drain the coolant in the radiator by

removing the radiator drain plug.

4 Remove the brace plate of radiator

Bolt

Brace

Plate

Radiator

Mounting

Bolt

7 Remove the four nos bolts (spanner size

12 mm) of fan blade & remove the fan
blade.

Fan

Fan Bolt

18

Engine

8 Remove the air cleaner by removing the

two nos bolts of air cleaner assembly.

Air

Cleaner

Mounting

Bolt

9 Remove the two Allen bolts each of suction

pipe & pressure pipe. (3/16 size bolt of
Pressure pipe & 7/32 of suction pipe).

11 Remove the suction pipe. (Suction pipe

below the transmission housing has to be
removed by removing two bolts with the
help of 7mm ratchet.)

Mounting

Bolt

Suction

Pipe

12 Remove the four nos of hydraulic pump

mtg. bolts (spanner size- 12/13) & remove
the hydraulic pump.

Hydraulic

Pump

Allen Bolt

for Suction

Pipe

1 0 Remove the hydraulic filter in suction line

by removing two bolts of it.

Mounitng

Bolts

Hydraulic

Filter

Hydraulic

Pump

Mounting

Bolt

13) Remove the two Allen bolts of hyd. Pump
bracket(10mm) and remove the hydraulic
bracket.

Hydraulic Pump

Mounting Bracket

Mounting

Allen Bolt

19

Engine

14 Remove the four nos bolts (13mm size)

stub pipe on exhaust manifold & remove
the stub pipe with silencer assembly.

Stub Pipe

Mounting

Bolt

1 5 Remove the steering wheel with the help

of steering puller

.

Steering Wheel

Puller

1 7 Remove the four nos of Phillips screws of

scuttle front panel by the screwdriver &
remove it.

Scuttle Pannel

Front

18 Disconnect all wiring harness couplers

connected to the scuttle.
1 9 Remove the pull to stop knob.
20 Remove the three screws of scuttle LH side

panel & remove the bonnet mtg. bracket.

Steering

Wheel

1 6 Remove the eight nos of Phillips screws of

scuttle top panel by the screwdriver &
remove it.

Phillips

Screw

Scuttle

Scuttle

Pannel LH

21 Remove the three screws of scuttle RH side

panel.

Scuttle

Pannel RH

20

Engine

22 Remove the accelerator linkage.
2 3 Remove the three nos of bolts of steering

mounting bracket (14mm- size) & remove
the bracket.

Steering

Gear Box

Mounting

Bolt

Fuel Tank

Mounting

Fuel Tank

Bolt

2 7 Remove the radiator mounting bracket by

removing the two nos bolts. (16mm).

2 8 Remove the four bolts (M12) of front axle

support. & remove the support.

24 Remove the two bolts of fuel tank

mounting bracket. (19mm Size)& remove
the bracket.

Fuel Tank

Extension

Tommy

Mounting

Bolt

2 5 Remove the nut connecting the drop arm

to drag Link.

26 Remove the two bolts of fuel filter &

remove the fuel filter to pump pipe.
Remove the filter.

Front Axle

Support

Mounting

Bolt

2 9 FAS will come along with the Front Axle.

3 0 Remove the two bolts of fuel filter bracket

& remove the bracket.

21

Engine

31 Remove the two nut of inlet manifold

(Spanner size :17mm) & remove the
manifold & gasket.

Mounting

Nut

Intake

Manifold

3 2 Remove the two Nut of exhaust manifold

(Spanner size 17mm) & remove the exhaust
manifold.

34 Remove the alternator by removing the

bolt.

Alternator

Mounting

Bolt

35 Remove the two bolts of alternator bracket

& remove the bracket.(Spanner size 8mm)

Mounting

Nut

Exhaust

Manifold

33 Remove the three bolts of (Spanner size

12mm) alternator brace & remove the
brace.

Alternator

Brace

Mounting

Bolt

Alternator

Bracket

Mounting

Bolt

36 Remove the two bolts of breather assembly

(Spanner size 10mm) and separate it.

Breather

Assy.

22

Engine

3 7 Remove the nut connected to the injector

& other nut on the crankcase (17mm), to
remove the Fuel Pressure pipe loosen the
clamp bolt.

Injector

Nut

39 Remove the two bolts of water pump &

remove it. (Spanner size 13mm)

Water Pump

Mounting

Bracket

40 Remove the hour meter adaptor by

removing two bolts.

Hour Meter

Adaptor

Fuel Pressure

Pipe

38 Remove the two clips of the hose between

the water pump and crankcase block.

Hose

Pipe

41 Remove the three bolts of hour meter

adaptor plate.

Hour Meter

Adaptor Plate

23

4 2 Remove the crankshaft pulley by removing

one bolt.( 16mm).

Crankshaft

Pulley

Dismantling procedure of the valve
housing cover & cylinder head

43 Remove the two bolts of the valve housing

cover & remove it.

Engine

Cylinder

Head

4 5 Remove the two nos bolts of rocker arm &

remove the rocker arm shaft. (Rail of rocker

arm).

Rocker

Arm

24

Engine Oil

Filler Plug

Valve

Housing

Cover

44 Remove the four bolts of the cylinder head.

(Spanner Size 3/4).

4 6 Remove the rocker arm & Push rods..
47 Remove the cylinder head from the

crankcase block.

Cylinder Head

Assembly

Engine

48 Valve Springs can be removed from the

Cylinder head by removing the lock.
Remove the top retainer, Spring, Bottom
retainer and thrust washer.

49 Remove the cylinder head block by

removing the dowel by pulling it.

Cylinder

Block

Dismantling procedure of the Piston
assembly .

5 0 Remove the circlip of piston pin.

Dismantling procedure of crankcase front
cover-

5 2 Remove the nine bolts of the front engine

cover.

Mounting

Bolt

Engine

Front Cover

5 3 Remove the engine front cover

Piston

5 1 Hammer the piston pin with a mallet and

remove the piston pin & piston.

Piston

Pin

5 4 Remove the gasket front cover.
5 5 Remove the spin on oil filter.
56 Remove the six bolts of the clutch cover

assembly (13mm).

Clutch

Assembly

25

Engine

5 7 Remove the clutch.

5 8 Drain the oil from the oil pan.
5 9 Remove the nuts of the accelerator lever

bracket.

Accelerator

Lever Bracket

Nut

6 1 Remove the three bolts to remove the fuel

injection pump (13mm).

Fuel Injection

Pump

62 Remove the fuel injection pump & its

gasket.

6 0 Remove the Accelerator lever bracket.

6 3 Remove the camshaft.

Camshaft

Gear

Camshaft

26

Engine

6 4 Remove the six nos Allen bolts (10mm) of

the flywheel assembly.

Flywheel

Mounting

Allen Bolt

6 4 Remove the flywheel.

Flywheel

Mounting

Allen Bolt

threaded portion fits into the spindle.
Tighten the lock nut such that the spindle
is pulled out along with the bolt.

Governor

Spindle

Remover

Special Tool

68 Remove the pin of the hand accelerator

lever.

69 Remove the spring connecting the

governor control lever with hand
accelerator lever.

6 5 Remove the pressure distribution plate.

Pressure

Distribution

Plate

Dismantling procedure of the governor
control shaft

6 6 Remove the inside circlip of the governor

control shaft with the help of the circlip
plier.

67 Remove the governor control spindle by

placing the puller (MST-H1-EN- )on the
Crankcase. Screw the bolt such that the

Governor

Spring

70 Remove the oil pump gear by tapping it

with the mallet.

Governor

Spring

27

Engine

71 Remove the crank gear with the help of

puller (SST MST-H1-EN- ).

Crank Gear

Puller

72 Remove the ball hub & disc of the ball hub

with the help of the puller.

7 3 Remove the nylon spacer.

Nylon Spacer

7 5 Remove the oil pump.

• The Oil Pump gears are non-serviceable.

• Oil Pump has to be replaced in case of

replacement required for gears
7 6 Remove the 12 nos bolts of the oil pan
7 7 Remove the oil pan.
78 Remove the two bolts of the connecting

rod cap & remove the connecting rod cap.

7 4 Remove the 6 nos bolts of the oil pump.

Oil Pump

Connecting

Rod

79 Remove the two allen bolts of crank

balance weight.
8 0 Remove the crank balance weight.(2 nos)
81 Remove the cam follower bracket & cam

follower by removing Allen bolts. (8mm)
82 Remove the relief valve assembly by

loosening the nuts.

28

Engine

83 Remove the 6 nos bolts of the flywheel

housing & remove the flywheel housing.

Flywheel

Housing

84 Remove the 4 nos bolts of the rear retainer

(17mm).

Crankshaft

Main Bearing

Retainer

8 6 Remove the crankshaft

Crankshaft

8 7 Remove the thrust washer.

Thrust

Washer

85 Use the two bolts as a puller & remove the

retainer.

Puller

Bolts

Puller

Bolts

Before Assembly ensure that

1 Use new gaskets, ‘o’ rings, Oil Seals and

fasteners.
2 All bearings must be cleaned & lubricated.
3 All moving parts must be smeared with

lubricants.
4 Smear oil on oil seal lip before fitment.
5 Use recommended Special Service tools.

Assembly :

Assembly is reverse of dismantling sequence.
Some of the important adjustments that needs
to be done are as follows :

29

Engine

Bumping

Clearance

Tool

The Crankshaft –gear has one dot on it which
should be matched with matching marks (two
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.
This has to be matched with the two dots on
the balancing gear. This Gear pair is provided
to reduce engine vibrations.

Bumping Clearance Setting ( Selection of
Shims below the Cylinder block):

1 Mount the Cylinder block on the crankcase

without shims.

2 Rotate the Crankpulley and get the piston

in T.D.C position.

3 Place the bumping clearance tool (MST-

H1-EN- ) on the liner top face without
cylinder head gasket. The tool can be
placed 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 the crankcase.

4 Rotate Crankpulley in clockwise/

anticlockwise and note the maximum dial
reading at TDC. This is to ensure that piston
is at the top dead centre position. If the
reading is ‘X’mm then the shims required
will be “ (X – 0.2 or 0.30) mm”.

Value of X will always be greater then

0.30mm.

FIP Mounting Setting : There is a value in mm
which is punched on the crankcase next to the
FIP.

1 Whenever the FIP is removed the no of shims

to be replaced should be equal to the value
on the Crankcase.

2 If FIP is to be replaced, then value on the

old FIP Should be noted.
3 Value provided on new FIP to be noted.
Now the revised number of shims = Value on

Crankcase – Value on old FIP x 0.1 + Value on
New FIP x 0.1

The shims are available in ‘3’ different
sizes : 0.4 mm, 0.3 mm and 0.2mm. The

Etched Value

on Crankcase

Cylinder

Block

Fuel Injection

Pump

30

Engine

Service Instruction for Air Cleaner Service

1. Remove oil bowl of air cleaner and drain
entire oil.

2. Remove primary & secondary wiremesh
element & clean them with diesel.

3. Remove foam element clean it in diesel and
squeeze it to remove dirt.

4. Apply 6 to 8 gms of oil uniformly on the
surface of foam.

Care Required While Assembling Crank Shaft

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
assemble it in to main body.

8. Check for perfect assembly.

9. Check the seal for perfect sealing condition
and replace it if necessary.

Loctite 5060 needs to be applied on the face of the Gear for Counter weight
at Crankshaft - 006009900B1, as highlighted in the images.

31

MAINTENANCE CHART FOR ENGINE

Job 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
Oil Level Check
Oil Change
Oil Filter Change
Valve Clearance Check
Low–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 at 500 hrs & then Change
every alternate service)

Injector Check

Cooling System

Radiator Fins Clean
Coolant - Water Check &

water T op Up
Radiator Cap Check
Fan Belt & Fan Belt Tension Check

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32

TRANSMISTRANSMIS

TRANSMIS

TRANSMISTRANSMIS

TRANSMISTRANSMIS

TRANSMIS

TRANSMISTRANSMIS

TRANSMISTRANSMIS

TRANSMIS

TRANSMISTRANSMIS

SIONSION

SION

SIONSION

SIONSION

SION

SIONSION

SIONSION

SION

SIONSION

Transmission Specification

CLUTCH

Make M & M
Type Dry Organic Facing type
No of Plate Single Plate
Outer Diameter (mm) 2 00
Thickness of Clutch plate (mm) 7. 2
Operating Method Pedal Operated

GEAR BOX

Make M & M
Type Sliding Mesh
Number of Gears 6 Forward & 3 Reverse

Gear Shift Pattern

Gear Shift Lever

Front Rear

Hi low Reverse Shift Lever

Front Rear

Transmission Oil (Including Hydraulic) EP90
Capacity 1 6
Oil Change Period Every 1000 Hrs
Crown Wheel & bevel pinion ratio 4.77:1
Final Drive gear ration (Bull gear ratio) 2 .933:1

BRAKE

Type Mechanical dry type

35

Transmission Torque Charts

Sr No Description T orque (Nm)

1 Transcase Cover to Transcase 21 - 25
2 Retainer Layshaft to Transcase 21 - 25
3 Retainer Splineshaft to Transcase 21 - 25
4 Retainer Rear Axle to RAC 21 - 25
5 PTO Housing to Transcase 21 - 25
6 Bull Cageto Transcase 41 - 50
7 RAC to Transcase 41 - 50
8 Clutch Hsg to Transcase 41 - 50

9 Cross Shaft to Ring Gear 41 - 50
10 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
15 Nut For Differential Stud 75 - 87
16 Bolt for Rail 41 - 50
17 Bolt for Reverse Idler Shaft 41 - 50
18 Lock Nut Bull Gear 110 - 120
19 Plug Magnetic Drain 68 - 75
2 0 Dipstick 47 - 54
21 Grease Nipple Clutch Release Sleeve 21 - 25
22 Grease Nipple Clutch Release Shaft 21 - 2 5
23 VTU to Transcase 64 - 75
24 VTU to Transcase 65 - 75
25 VTU to Transcase 41 - 50
26 VTU to Transcase 65 - 75

36

Transmission

General :

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. Three point Linkages

6. Seat assembly

7. Scuttle assembly

8. Steering assembly
Jack the tractor with proper jack or hoist

Remove the transmission breather / dipstick for
free flow of transmission oil.

Breather /

Dipstick

Removal of Clutch Housing & Connection

1. Remove the bolts mounting the clutch
housing to engine.

Jack

Loosen the bolts of the tyre & remove both the
tyres.

Loosen the drain the plug of the transmission
& drain the transmission oil.

Mounting

Bolt

2. Separate the engine form the clutch
housing.

3. Remove the spring of clutch release sleeve
& remove the clutch release sleeve with
bearing.

Spring

Clutch Release

Sleeve

37

Transmission

4. Remove the Clutch housing hand hole
cover by removing 6 nos of bolts mounting
it on the clutch housing.

5. Remove the clutch release bearing shaft &
fork as follows

Release

Fork

a. Remove 2 nos of bolt & spring washer

of clutch release with the help of
spanner.

b. Remove the RH circlip of clutch release

shaft

c. Tap the clutch release shaft from the RH

side with the help of mallet.

d. Hold the fork with one hand & pull out

the clutch release shaft by other hand.

Note:- The clutch release shaft has a circlip
on the LH also which acts as retainer & avoids
fouling of actuating portion of the shaft with
the housing.

9. Remove the coupling by removing the roll
pins with the help of roll pin punch.

Coupling

Roll

Pin

10. Clean all the parts with the help of cleaning
fluid & inspect of wear & damage if found
beyond permissible replace the same with
new one.

Note: Always use new gaskets & roll pins at
the time of assembly.

Dismantling of Rail Assembly

Hi, Low & Reverse

Lever

Gear Shift

Lever

38

6. Remove the 8 nos of bolts mounting the
clutch housing to the transmission case.

7. Remove the clutch housing in straight
direction, if not the 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.

Roll

Pin

Drive
Shaft

Transcase

Cover

1. Remove the Hi Low Reverse shift lever by
removing the double roll pin with help of
roll pin punch & hammer.

2. Remove the cotter pin & plain washer of
the link actuating the gear shift rail.

3. Remove the external circlip of gear shift
lever with the help of circlip plier .

4. Remove the washer retaining the gear shift
lever.

5. Then remove the gear shift lever with
actuating link.

Transmission

6. Remove the Top cover of transmission case
by removing 10 nos of bolts with the help
of spanner.

Mounitng

Transcase Cover

Bolt

7. Remove the roll pin of section shifter with
help of roll pin punch & make the section
shifter free on it individual rail.

Hi-Low,

Reverse Rail

13 . Remove the rail holding the shifting forks

by tapping it for the rear end (Differential
side).

Fork

Rail

Note:- The rail has spring & ball on it at the
forks.

14 . Remove the forks form the transmission.

15. Clean all the parts with the help of cleaning
fluid & inspect all the parts for wear &
damage, replace if necessary.

Note: Use new seals, roll pins, cotter pins &
gaskets at the time of assembly.

Gear Shift

Rail

Section

Shifter

8. Hold the Hi low reverse section shifter with
one hand & with other tap & remove the
Hi Low Reverse rail from the transmission.

9. Remove the Hi Low Reverse section shifter
& oil seal of it.

10. Remove the RH external circlip & washer
of gear shift rail with the help of plier.

11. Hold the gear shift section shifter with one
hand & with other tap & remove the gear
shift rail from the transmission.

12 . Remove the gear shift section shifter.

Dismantling of PTO Assembly

1. Remove 10 nos of bolts & spring lock
washer of rear PTO cover with the help of
a 8 mm spanner.

Mounitng

Bolt

PTO Cover

2. Slightly tap on the PTO cover on the edge
with the help of mallet

39

Transmission

3. Pull out the PTO shaft subassembly by
holding the main PTO shaft.

Main PTO

Shaft

4. Damage & remove the welch plug mounted
on the rear cover.

Welch

Plug

6. Remove the PTO drive shaft by tapping it
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.

8. Tap & remove the bearing of PTO shaft
drive shaft.

9. Remove 3 nos of bolt & spring lock washer
of PTO oil seal retainer with the help of 8
mm spanner.

Bolt

Main PTO

Shaft

5. Remove the rear circlip of the PTO drive
shaft with the help of external circlip plier.

Circlip

10 . Pull & remove the PTO oil seal retainer.
11 . Remove the PTO oil seal.

12. Remove the front & rear circlip of main PTO
shaft.

Front

Circlip

40

Transmission

13 . Remove the shims of PTO shaft.

14. Tap the main PTO shat with the help of
mallet form the front side & draw the main
PTO shaft from the rear.

Mallet

Main PTO

Gear

15 . After removing the main PTO shaft, draw

out the PTO gear with front & rear PTO shaft
spacer.

Main PTO

Gear

Front

Spacer

Bearing

Main PTO

Shaft

Bearing

Rear

Spacer

18 . Remove the roll pin of PTO shift lever with

the help of roll pin punch & draw out the
PTO shift lever with ball & spring.

19. Remove the bolt & spring lock washer of
PTO shifter shaft retaining plate with the
help of 8 mm 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 cleaning
fluid & inspect all the parts for wear &
damage, replace if necessary.

Note: Always Use new seals & circlips at the
time of assembly.

Dismantling of Brae Assembly

1. Remove 4 nos of hexagonal headed bolts
& washer, mounting the brake assembly to
the transmission with the 10 mm spanner.

16. Remove the remaining bearings.

17. Remove the PTO coupling.

Coupling

PTO

Brake

Assembly

Mounting

Bolt

2. Remove the Brake assembly with friction
disc & actuating disc assembly.

Brake Assembly

41

Transmission

3. Remove the breather.

4. Remove the cotter pin of the actuating disc
pull rod & remove the bolt of the pull rod.

5. Remove the pin of the tension link by
removing the cotter pin & washer with pin
mounting the tension link on the brake
housing.

6. Pull out the actuating assembly.

7. Remove the rubber boot mounting on the
brake housing.

8. Remove the friction disc.

9. Dismantling of actuating disc assembly.
a. To remove the actuating disc assembly

from the brake assembly remove the pin
connecting the pull rod & crank link by
removing the ‘R’ pin.

Dismantling of Reverse Idler Assembly

1. Remove the grub screw retaining the
reverse idler assembly on the transmission
case with the help of 10 mm spanner.

Grub

Screw

2. Tap & remove the reverse idler assembly
with the help of mallet from the rear side
of the transmission.

b. Remove the pull rod & actuating unit

assembly from the housing.

c. To separate the two actuating disc,

remove the 2 nos of springs holding the
disc together with the help of screw
driver or plier.

d. Remove the 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
fluid except the friction disc & inspect all
for wear & damages. If found beyond limit
replace the same with new one.

Reverse Idler

Shaft

Reverse Idler

Gear

3. Remove the external circlip retaining the
reverse idler gear in the reverse idler shaft
with the help of external circlip plier.

4. Remove the thrust washer.

5. Remove the reverse idler gear from the
shaft.

6. Remove the snap ring from the reverse idler
gear & remove the 2 nos of needle roller
bearing from it.

42

Transmission

7. Clean all the part with the help of cleaning
fluid & inspect them for wear & damage,
replace if found worn & damage.

Note: While assembly ensure that the reverse

idler shaft half cut portion is on the top
side & match the hole of the reverse idler
shaft with the help of a round rod. (The
half cut on the reverse idler shaft is
provided for lubrication of the reverse
idler assembly.)

Half Cut

Portion

Dismantling of Differential Assembly

LH Bull

Cage

Crown

Wheel

Adaptor

RH Bull

Cage

2. Tap & remove the bull cage LH & RH with
the help of mallet. Hold the differential
cage assembly while removing the bull
cage assembly LH & RH.

3. Remove the adaptor of bull cage LH & RH
with the help of screw driver.

Adaptor

4. Remove the shims mounted on the bull
cage.

LH Bevel cum

Bull Shaft

RH Bevel cum

Bull Shaft

1. Loosen & remove 6 nos each bull cage
mounting bolt form bull cage RH & LH with
the help of 10 mm spanner.

Mounting

Bolt

Shims

5. Remove the Bull cum Bevel gear shaft from
the cage with the help of mallet from both
LH & RH.

Bull Cum Bevel Gear

6. Remove the circlip of bull cage bearing &
remove the bearing.

7. Unlock the lock plate of the bull shaft &
remove the nut with lock plate form the
bull shaft.

43

Transmission

8. Remove the integral stud, inserted in the
bull shaft.

Integral

Stud

9. Dismantling of differential cage assembly.
a. Unlock the lock plate of bull cage cross

shaft & remove the 5 nos of bolts
mounting the cross shaft to the crown
wheel. The cross shaft will come out
with the bevel pinion gear.

Cross

Shaft

Mounitng

Bolt

Lock Plate

2. Unlock the lock plate of bull gear locking
nut & remove the lock nut with the spanner .

Lock

Nut

3. Remove the bull gear & conical spacer from
the transmission.

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 the help
of mallet till it comes out from the inner
bearing of the rear axle carrier.

b. Remove the bevel pinion gear & bevel

pinion shaft

10. Clean all the part with the help of cleaning
fluid & inspect all the parts for wear &
damage. Replace if found, with new one.

Note: Always use new seals & circlips at the
time of assembly.

Dismantling of Rear Axle Assembly

1. Jack the rear axle assembly with the help
of hydraulic hoist & chain.

6. Further tap on the rear axle wheel
mounting area in diagonal sequence with
the help of mallet till the rear axle comes
out.

7. Remove 4 nos of bolts & washer of rear axle
retainer with the help of 8 mm spanner &
remove the rear axle retainer.

8. Remove the oil seal form the retainer.

9. Remove the inner bearing by remove the
retaining circlip with help of circlip plier,
also remove the outer bearing.

10. Clean all the parts with the help of cleaning
fluid & inspect all the parts for wear &
damage, replace defective & worn out
parts with new ones.

Note: Use new seals, lock nuts & circlips at
the time of assembly.

44

Transmission

Dismantling of Counter Shaft Assembly
(Driving Shaft Assembly)

Counter Shaft

Retainer

Counter

Shaft

2nd & 3rd

Driving Cluster

Gear

Bearing

1. Remove the 3 nos of bolts & washer of
Counter shaft retainer with the help of 8
no. spanner.

Retainer

Hi-Low &

Reverse Cluster

Gear

Bearing

Mounting

Bolt

Counter Shaft Retainer

Bearing

Spacer

2nd & 3rd Driving

Cluster Gear

Counter

Shaft

Spacer

Hi-Low & Reverse

Cluster Gear

Bearing

Spacer

6. Hold the 1st & 2nd driving gear with one
hand & with other hand pull out the
counter shaft out of the transmission case.
Remove the 1st & 2nd driving cluster gear
with shims & rear spacer from the
transmission.

7. Remove the bearings from retainer, mid
wall of transmission & rear wall of the
transmission. To remove the retainer
bearing & rear transmission bearing first
remove the circlip form the transmission.

8. Clean all the part with the help of cleaning
fluid & inspect all the part for wear &
damage, replace with new one if found.

2. Remove the retainer with oil seal by tapping
the retainer with mallet.

3. Remove the rear circlip on the counter shaft
with the help of circlip plier.

4. Slightly tap the counter shaft from the rear
end with the help of mallet.

5. Hold the Hi low Reverse cluster gear with
one hand & with other pull out the counter
shaft from front side till the Hi low reverse
cluster gear is free to come out from the
transmission case. Also, remove the spacer
which is at the front & rear end of the cluster
gear. The cluster gear has 3 nos of needle
roller bearing & 2 nos of plastic bush inside
it.

Note: Always use new Oil seals & circlips at the
time of assembly

Dismantling of Spline Shaft Assembly
(Driven Shaft Assembly)

Circlip

Spacer

Bearing

1st Gear Driven

2nd & 3rd

Gear Driven

Spacer Spline

Shaft

Bevel Pinion

Hi-Low Gear

Shaft

Double
Bearing

45

Transmission

1. Remove the 3 nos bolts & spring lock
washer with the help of 8 no. spanner.

Mounting

Bolt

2. Remove the spline shaft retainer with the
help of mallet.

Retainer

4. Unlock the lock plate of the Pinion shaft &
remove the bolt with lock plate & stopper
plate of Pinion shaft.

Stopper Plate

Bolt

5. Tap the spline shaft slightly with the help
of mallet.

6. Hold the Hi low driven gear with one hand
& with other pull out the pinion shaft
which has double ball bearing, spacer &
circlip. Also remove the Hi low driven gear
& shims from the housing.

3. Remove the circlip of the spline shaft front
end.

Circlip

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 stepped spacer.

8. Remove the spacer mounted on the spline
shaft & remove the 2nd & 3rd driven cluster
gear.

9. Remove the spline shaft with mid bearing
& circlip from transmission case.

10. Remove the circlip & remove the bearing
of the spline shaft.

11. Remove the front bearing, oil seal from the
retainer & double bearing from the spline
shaft.

12. Clean all the part with the help of cleaning
fluid & inspect all the part wear & damage
replace with new one if found.

Note: Always use new oil seals & circlips at the
time of assembly.

46

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

47

HYDRAHYDRA

HYDRA

HYDRAHYDRA

HYDRAHYDRA

HYDRA

HYDRAHYDRA

HYDRAHYDRA

HYDRA

HYDRAHYDRA

ULICULIC

ULIC

ULICULIC

ULICULIC

ULIC

ULICULIC

ULICULIC

ULIC

ULICULIC

SS

S

SS

SS

S

SS

SS

S

SS

Hydraulic Specification & Torque Values

Hydraulic Specifications
The Pump

Make Dowty
Type Gear
Capacity (cc/rev) 7.03
Output @ 2300 Engine RPM (lpm) 1 6

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) 47.03 - 46.98

Bell Crank

Bell Crank Pin (mm) 20.00 - 19.9

Torque Values

Sr No Description T orque (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 Bolt 20 to 25

5 Quadrant Mounting Bolts 35 to 40

6 Control Valve Mounting Bolts 95 to 101

7 Draft Sensing Bolts 96 to 102

8 Hydraulic Mounting Bolts 41 to 45

9 Hydraulic Mounting Studs 55 to 60

10 Hydraulic Mounting Nut 41 to 45

11 DC Sensing Nut 15

12 DC Sensing Lock Nut 25

51

Hydraulic Torque Values

a desired height

Position control set to give

Lever

1

2

4

3

Draft Control

Lever

Position Control

Upper Limit

Stop

Position

Control

756

Arrangement of Position Control Linkages

1 Lever Position Control
2 Lever Draft Control
3 Cam

Control set for Transporting

4 Roller

1

desired height

Position Control Set to give a

9

2

5 PC Actuating Link
6 Spring
7 Spool

8 7 56

3

4

52

Arrangement of Draft Control Linkages

1 Lever Draft Control
2 Rocker Draft

Control
3 Top Link Crank
4 Lift Arm

a desired height

5 Link Outer Draft

Position Control Set to give

Sensing
6 Spring DC Rod
7 Cable
8 Link Cpte. DC

Actuating
9 Spool Control

Valve

Hy-tec Hydraulics

Schematic Layout Showing Details of Control Valve

Components in Neutral Position

53

Hy-tec Hydraulics

Sr. No Description

1. Pump Inlet

2. Spacer Compensator

3. Sleeve Compensator

4. Spool Compensator

5. Spring Compensator

6. Retainer Plug

7. Orifice

8. Spring Regulator Valve

9. Ball Regulator Valve

10. Regulator Piston
11 . Valve Plug
12 . Relief Valve
13 . Ball Rider Relief Valve
14 . Spring Relief Valve

Sr. No Description

21. Tank Port

22. Main Plug

23. T ank Port Bypass
24 . Orifice (0.8 mm dia)

25. Seat Check Valve
2 6 .Ball Check Valve

27. Spring Check Valve

28 . Sleeve Check Valve II. Valve Plug
29 . Rider Check Valve

30. Retainer Check Valve

31. Spring Check Valve Retainer

32. Auxiliary Port

33 . Isolator Valve

34. Lift Cylinder

15 . Housing Relief Valve

16. Spool Control Valve

17. Sleeve Control Valve

18. Pilot Port Sleeve CV

19. Lifting Port Sleeve CV

20. Lowering Port Sleeve CV

35. Tank Port Regulator Valve

36. Tank Port Lowering

37. Piolet Line

38 . Spring Main Valve
39 . Relief Valve Reservoir Port

54

Lifting Position

Hy-tec Hydraulics

55

Lowering Position

Hy-tec Hydraulics

56

Hy-tec Hydraulics

General

1. Description

These tractors are equipped with ‘Vary
Touch’ hydraulic system consist of an
engine driven gear type pump, lift housing
connecting pipes and filter.

The reservoir is transmission housing. The
oil is common for a transmission and
hydraulics. The strainer is fitted on
transmission, addition paper filter in
corporated on suction line, with as ensured
100% filteration, Lift cylinder, control
valves, control valve linkage and rock shaft,
carries the lift arm for the three point
linkages. The control valves provided a jack
tapping to accommodate a self sealing
coupling which provides hydraulic power
to any equipment fitted with single acting
hydraulic cylinder. A bell crank lever
housed in the rear frame carries a top link
which act as a sensing arm with control
valve linkage.

2. Principle of Operation.

The direction of flow is from the pump
through the reponse compenseter valve,
spool control valve to cylinder and non
return valve / checke valve is the regulator
and the restricting orifice which also
connect to the sleve control valve assembly .
The draft and lowering the system is
prodected by a relief valve between the
pump and response control (compensator)
valve.

The control valve is operated by two levers.
The inner lever control the implement
position and outer lever controls Implement
draft. When one of the levers is in use, the
other lever MUST be in the fully forward
position to close the lift port and open the
lowering port of the circuit. Thus the only
flow delived to the cylinder is that
controlled by the lever in use.

When the spool in use is in neutral or hold

position 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 will have
more effect on the greator face thus
moving the piston to hold the regulator
ball (9) off its seat allowing pressure oil to
pass the ball and return the reservoir
through the regulator port (35).

When the spool is moved to open the lift
port (18) to reservoir, the resulting flow
through restricting orific will cause the
pressure drop at the regulator allowing the
regulator ball to seat. The pressure will
then open the non return valve/check valve
against its spring and allow pressure to
reach the flift cylinder.

When the spool is moved to lower , the flow
through the restrictor port / pilot port (18)
is stoped to un seat the regulator ball and
allow pressure from the cylinder discharge
through the lowering port (36). The non
return valve / check valve. Closes due to its
spring to prevent return oil entering the
pressure line.

a. Position Control (Dia. Pg No.57)

When the positon control lever (5) is moved
to LIFT, the PC actuating link (6) pushes the
spool (10) in control valve (11) under the
action of return spring opening the pilot
port (18). The resulting pressure drop
allows the regulator ball to seat and
pressure is directed to the cylinder.

As the rocks shaft rotate and the lift arms
and implement lift, the PC cam contacts the
PC roller assy to move the PC linkage (6)
and plunger to closed the pilot port. The
regulating pressure built up, moves the
regulator piston to unseat the regulator
ball allow pump pressure to discharge to
reservoir through the regulator port (35).
The lift arms and implement are then held
by the oil locked in the cylinder (34). When
PC lever (5) moved to lower the PC

57

585960

Hy-tec Hydraulics

actuating link pivots about PC roller assy
(2) and moves back towards rockshaft. This
allows spool (10) to come out under the
action of spring main valve (38). This allow
the oil to return from lift cylinder and
discharge to the reservoir causing the lift
arms and implement to lower under their
own weight.

As the rocker shaft (12) rotates, the rock
shaft cam tends to move away from the
roller (2) and, in following the cam profile
the roller and linkage allow the plunger to
move out until the spool control cover the
sleeve port (20) then the lift arms and
implement are again held by the oil locked
in the lift cylinder (34).

As the pump pressure is unchanged the
regulator ball will be held off its seat and
pressure oil discharges to reservoir.

NOTE : The distance raised depends
onthe movement of the position control
lever in quadrant.

b. Draft Control (Dia. Pg 58)

The draft control system operate on the
principle of draft loads i.e. resistance acting
on the implement while it is being pulled
through the ground. Load, actuates the DC
feedback link outer assy (5) which is linked
to the draft control spool of the valve.

The position of the draft control lever (14)
corresponds with a definite resistance of
the implement being pulled through the
ground.

The implement penetrates into the ground
until the pre selected operating resistance
is reached. At this point the draft control
linkage top link, bell crank / top link crank
(1) (sensing element) acts on DC feedback
link outer assy (5) which in turn transfer
motion to DC feedback rod (8) which is
connecting to DC actuating link (12) which
actuates spool control lever (22).

An increase in implement 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 pressure drop allow the
regulator ball to sear and pressure is
directed to the cylinder to raise the lift arms
and implement. As the implement is raised,
the compression load on the top link is
reduced and by the top link crank (1) will
go back and allow the spool control valve
(22) to move out by action of feedback
spring. The spool cuts off the pilot port and
resulting pressure rise unseats the regulator
ball to allow pump pressure to return to
reservoir. A decrease in implement draft
allow the Link outer draft sensing to move
back taking the spool control valve with it.
This uncover the lowering port, allowing
the lift arms and implement to fall until the
increase in implement draft moves the
control spool through the linkages to close
the lowering port.

The draft control lever (14), by moving the
rocker draft control (13) of the operating
link / link cpte DC actuating move the draft
link relative to the DC feedback link outer
assy this movement is transmitted to the
control spool and oil flows in the
appropriate direction until the resulting
movement of the lift arms brings the
implement draft to the desired setting. The
spool then returns to the neutral position
to cut off the oil flow.

c. Draft control / sensing element.

1. The Tension or pressure forces acting on
the Top link sensing element are converted
into control signal i.e.

These signal are taken up by the Top link
crank (1) and transmitted to the spool control
valve (22) for lifting or lowering action.

2. Operation
In draft control mode, the lever (14) is set

at particular position on the quadrant, top
link attached to top link crank (1), under

Hy-tec Hydraulics

the top link force the top link spring (19)
(20) will deflect. This displacement is
passed to link outer draft sensing (5). The
movement of link outer draft sensing is
transfered to spool control valve (22) with
certain amplification through DC feedback
rod (8) and link DC actuating (12). This
results in lifting of implement in operation
till the set force is reached. If the implement
is lifted more then required which will
reduce the top link crank back ward will
lower the hitch till the set draft is achieved.

d. Check Valve

The ball is kept on its seat by the spring until
pressure in the pump line is approximately
75 PSI. This ensure that in the drop position
the lift arm fall will not be allowed by low
pressure oil, which is circulated by the pump
to the reservoir through the regulator port
the check valve also locks the oil in the
cylinder when controls are in the natural (or
hold) position.

e. The Relief Valve

The relief valve ball become unseated
allowing the high pressure oil to drain to
the reservoir through port when the
pressure in the system exceeds the specified
figure and overcomes the spring. The relief
valve is not adjustable.

f. Cylinder cushion valve

This valve is fitted on the cylinder pistion.
The purpose of the cylinder cushion valve
is to protect the system against shock loads
when driving over a bumpy road with a
bouncing implement. 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 in the power cylinder.

CAUTION :

position control lever against the upper
limit stop

Never drive with the

g. Remote Cylinder

To operate, single-acting cylinders, the
adjustable stop is moved to contact the
upper limit stop, the position lever is then
used to raise the lift arms full. Close the
isolating valve. With the position lever
against the adjustable stop, the remote
cylinder is in the neutral or hold position.
To operate the remote cylinder the lever is
spring over the adjustable stop until it is in
contact with the limit stop. The valve
operation for remote cylinder LIFT and as
soon as, cylinders are extnded, return the
position lever to the hold position. To allow
the cylinder to retract, move the lever
forward from the hold position

4. TEST PROCEDURE

a. General

Before Investigation any service problem
the following basic points should be
checked Hydraulic system that has failed
step by step.

– Fluid level
– Age condition, and type of fluid
– External leakage
– Air in the system
– Operating temperature of 50º–20ºC.

The Test procedure covers the following tests.

1. Hydraulic pump capacity

2. Plain relief valve setting

3. Cylinder cushion valve setting

b. Hydraulic pump capacity may be

measured when pump is installed, or on
a test bench.

Test valves see specification.
Pump is designed for 16 Lts.
Maximum permissible operation speed

2500 rpm.

61

Hy-tec Hydraulics

Maximum permissible pressure (Hydraulic
lift element) 207 bar.

Repair or replace the pump if capacity is
less than 75% of normal value.

c. Relief valve pressure

Install a pressure gauge (-0-210 kg/cm
140 bar in the external jack tapping.
(auxiliary port) with the draft control lever
in the top most position and the engine at
full throttle the pressure should be as per
specification.

WARNING :

1. To avoid over heating of the system the
pressure test should not be maintained for
more than 30 seconds.

2. After completion of the test the draft
control lever must be return to the deepest
position other wise serious damage to the
hydraulic system may result. If the recorded
pressure is not as per the specification while
the relief valve is operating, the relief valve
spring must be checked.

With the control lever in “Lower” there
should be no more than 0.127mm drop of
the lower link ends in 30 seconds.

WARNING :

Open the isolating valve

fully after the above test.

g. Position Control Valve Leakage Test

2

)

Fully lift the weights (600kg) then return
the position control lever to a mid position.
There must be no more than 0.3mm drop
of the link ends in 30 seconds.

With the lever in the lowest position the
link ends must be not more than 127mm
from the ground.

If the relief valve is OK and not getting
specified pressure, either the compensator
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 position, the gauge should
read zero.

e. Speed of Lift and Lower

Move the position control to lift. Full lift
should be completed in not more than
three seconds.

Move the lever to lower and check that it
is possible to control the drop so that at
least two seconds are taken for a full drop.

f. Isolating Valve Leakage

Raise the weights fully then close the
isolating valve.

62

Hy-tec Hydraulics

1

9

7

8

1. Main Spool Valve Bore

2. Relief Valve Bore

3. Plug Connecting Check Valve to Control Valve

4. Plug Connecting Cylinder to Control Valve

5. Lowering Port Connecting Control Valve Spring
chamber to Tank

6. Bypass Tank Port

7. Plug Connecting Pump, Relief Valve & Control Valve

8. Port Conecting Regulator Bore to reservor

9. Regulator Valve Bore

2

3

4

5

6

j. 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-H1/2­HD-11

h. Position Control Valve Lift — Lower Test

Locate the position control stop at about
mid range.

Fully raise the lift arms then lower until the
control lever is against the stop.

Measure the height from the centre line of
the lower link 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
the ground. If these two measurements
differ by more than 25.4mm. The control
valve spool may sticky.

i. Noise

There should be no noise from any part of
the hydraulic system apart from a slight hiss
caused by oil flow.

c. Connect the hand pump (injecter tester) to

the external jack tapping.

d. Screw in the isolator valve.
e. Hole the spool at the full lift position

(inside).

63

f. Raise the pressure to 125-140 kg/cm2. 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.

g. IF oil is coming out from coupling 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. After reassembling, observe the pressure

guage, if the pressure is coming down, and
if oil is leaking from clearance between
main spool and sleeve is more than (0.010-

0.012) mm. Replace the spool with the
spool of bigger diameter and do necessary
lapping.

Hy-tec Hydraulics

64

Hy-tec Hydraulics

Dismantling procedure of the hydraulics.-

A) Dismantling procedure of the bell crank

Assembly-

1 Remove the M14 lock nut of the crank

toplink assembly.

Crank Toplink

Assy.

Lock Nut

2 Remove M14 Flange nut on the crank

toplink.

4 Remove the M8 bolt of pin crank top link.
5 Remove the pin crank top link.

Pin Crank

Toplink

6 Remove crank top link.
7 Remove ‘2’ bolts (M12 x 1.75) of draft

sensing mounting assembly.

3 Remove the step bolt DC outer block of DC

Connecting link.

DC feedback

link outer

assy

Step Bolt

Draft
Sensnsing
Mounting

Assembly

8 Remove sleeve draft sensing

Outer DC

Sleeve

Sensing Spring

Retainer

Inner DC

Sensing Spring

Draft Sensing

Spindle

65

Hy-tec Hydraulic

9 Remove outer DC sensing spring.
1 0 Remove inner DC sensing spring.
1 1 Remove Spindle Draft Sensing..

1 2 Remove sensing bottom sleeve.
13 Remove external circlip of the DC feedback

link & remove draft sensing link.

B) Removal of Control Valve assembly.

1 Remove the 8 bolts (1/2” UNC) of the CV

Assembly with spring washer.

Control

Valve

2 Remove the control valve. Remove two

small attaching cap screw and draw of the
cylinder head realising spring.

DC feedback

link

1 4 Remove the roll pin of DC outer rocker.

DC Outer

Rocker

8 Remove the spacer of DC Outer rocker.

Roll Pin

Spacer DC Outer Rocker

C Removal of Linkages -

1 Remove cotter pin of DC linkage.

DC Linkage

Cotter Pin

66

Hy-tec Hydraulic

2 Remove the clevis pin.

Clevis Pin

3 Remove the DC inner rocker assembly.

DC Inner

Rocker

DC Outer

Link

Bush

Oil

Seal

Spacer

DC Inner

Rocker

Clevis

Pin

5 Remove bolt from cam of cable DC

feedback.

Bolt DC

Feedback

Cable

4 Remove Bush DC Feedback shaft.

Bush

6 Remove DC rocker Allen Screw.

7 Remove DC rocker assembly.

DC Rocker

Assembly

67

Hy-tec Hydraulic

8 Remove Allen Screw of PC rocker.

Allen

Screw

9 Remove the PC link assembly.

PC Rocker
Assembly

D Removal of Quadrant assembly.

1 Remove two bolts of quadrant assembly

(Bolt Size M10 x 1.5)

Quadrant

Bolts

2 Remove quadrant assembly.

1 0 Remove the PC roller assembly.

PC Roller
Assembly

Quadrant
Assembly

68

Hy-tec Hydraulics

3 Remove the two bolts (M10 x 60) of plate

spring retainer.

Plate

Retainer

Bolts

4 Remove plate spring retainer.

Bolts

6 Remove the Quadrant spring.

Quadrant

Spring

7 Remove the two bolts of quadrant strip.

(Spanner Size15mm)

Spacer

Quadrant

5 Remove spacer quadrant draft control.

Bush

Spacer

Quadrant

Bolts

Quadrant

Strip

8 Remove the quadrant strip & DC slider.

DC Slider

69

Hy-tec Hydraulic

8 Remove the circlip from PC tube.

Circlip

PC

Tube

9 Remove DC lever Assembly.

DC Lever
Assembly

1 2 Remove friction disc.
1 3 Remove PC lever assembly.

Remove

Circlip

PC Lever

5 Removal procedure of power train

1 Remove circlip of rockshaft (RH)

Lift Arm

70

1 0 Remove friction disc.
1 1 Remove plate friction retainer.

Friction

Retainer

Friction Disc

Rocker

Shaft

2 Remove lift arm (RH)

Lift Arm

Circlip0

Hy-tec Hydraulics

3 Remove LH side circlip of rockshaft
4 Remove locking bolt of cam rocker arm.

(13mm)

Cam

Mounitng

Bolt

Rocker arm

mouting bolt

5 Remove LH lift arm.
6 Remove both side oil seal.
7 Remove the both side washer oil seal.
8 Loosen & Remove the Cam and rocker arm

mounting bolt.
9 Remove rockshaft from LH side only.
10 Remove two bushes (Only if Worn out )

from LH & RH.
1 1 Remove rocker arm with connecting rod.
a) Remove spring (rollpin) of connecting

rod.
b) Remove connecting rod.
c) Remove rocker arm.

ADJUSTMENTS

a. Adjusting the Position Control

Connect the lower links to a dead weight
of 450kg.

Open the isolating valve and set the draft
lever to the deepest position. Lift the
weight by operating position control lever
slowly until the distance from the center
line of the top hitch pin to the center line
of the lift arm pin is 620mm lock the
position control lever stop firmly behind
the lever in touching position.

NOTE : C heck that this is correctly set by

lowering 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. Checking the relief valve pressure. Fit

2

pressure gauge (0-214 kg/cm

) in the
external jack tapping. Close isolating valve.
Put engine to full throttle and lift the draft
control lever in the top most position the
pressure reading should be as per

2

specification (123-157 kg/cm

WARNING

!

:

system the pressure test should not be

To avoid overheating the

)

maintained for more than 30 seconds.
After completion of the test the draft

control lever must be returned to the
deepest position otherwise serious
damage to the hydraulic system may result.
If the recorded pressure is not 154-168 kg/

2

. It can be increased or decreased by

cm
adding or removing shims in the relief valve
sping housing. Addition of one 0.076 mm

2

will increase by 3.5 Kg/cm

and removal of

one shim will decrease the pressure by 3.5

2

Kg/cm

.

SERVICE INSTRUCTIONS
a. Adding Oil

After every 250 hrs of operation, check the
level of oil in the transmission reservoir.

71

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. as per procedure mentioned below.
1 ) Put a clean tray below suction line filter.
2 ) Unscrew the filter cartridge and collect the

oil in the tray.
3 ) Apply oil on ‘O’ ring of the new filter.

4) Assembled it with hand as per give

instruction on the filter.
5 ) Add oil if necessary.
6 ) Remove air as per instruction given below.

c. Changing the oil

Hy-tec Hydraulic

After every 1000 hrs. of operation system

should 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, remove the

orifice filter, clean or change.

3) Grip the suction strainer stub pipe near the

base & pull it out.

4) Clean the strainer in clean diesel fuel, using

a soft brush, then blow dry with

compressed air and replace with new if

necessary.

5) Install the drain plug on transmission

housing then fill the reservoir upto the

slotted mark of dipstick.
6 ) Run the engine for approximately for one

min. this will expel the air from the system

& allow the reservoir to be filled to

capacity.

72

7) If additional cylinders are used then add

extra oil with respected to cylinder capacity .
8 ) Install the fill plug cum dipstick.

Hy-tec Hydraulic

TROUBLE SHOOTING

TROUBLE PROBABLE CAUSE REMEDY

Hitch lifts slowly
(Not lifting with full speed)

Implement does not reach
maximum height

 Oil level in reservoir is low



Fall in pump efficiency

 Suction strainer! Suction line filter

clogged

 System overloaded
 Spring relief valve has taken

permanent set

 Spring compensator damaged
 Spring regulator valve damaged
 Regulator piston ‘O’ ring damaged or

not fitted properly

 Compensator spool stuck in fully open

position.

 Thermal relief valve is leaky.
 In draft control draft control feedback

link adjustment disturbed.

 Load movements restricted
 Hydraulic rock shaft, cam, lift arms,

improperly assembled

 Improperly set three point Linkages

Fill to correct level
Replace or repair the Pump
Clean strainer! replace filter

Reduce load
Replace the spring

Replace the spring
Replace the spring
Replace ‘O’ ring

Clean or replace if required

Replace
Adjust the draft control feedback

link, adjusting link length
Remove restriction
Check & assemble properly

Adjust

Lift coming down when
engine is stopped jerking
when engine is running

(A)

 Piston oil seal or piston relief valve

leaking

 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,

damaged ball sleeve, damaged valve
seat “O” ring

Fit new seals or relief valve

Fit new ‘O’ ring.
Change ‘O’ ring
Replace

Check spool fit, replace
components if required.

Check ball surface, ball seat,
damaged valve seat “O” ring &
replace if required.

73

TROUBLE SHOOTING

TROUBLE PROBABLE CAUSE REMEDY

Hy-tec Hydraulic

Noisy System

Regulator valve not opening
(oil flows through relief
valve when lift arms are
fully raised

Links creep up when
working with external
cylinder

 Low oil level
 Clogged suction strainer
 Air in the system

 Load movement restricted

 Restriction in high 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 valve is leaking

Fill to correct level
Remove and clean
Check oil level and suction

line joints
Check for free movement of

the links and that load is not
fouling tractor

Remove and clean

Check the unions and
tighten.

Repair or replace
Adjust

Clean

Remove and correct

Close

Rectify / replace

74

FRONT AXLE &FRONT AXLE &

FRONT AXLE &

FRONT AXLE &FRONT AXLE &

FRONT AXLE & STEERINGFRONT AXLE & STEERING

FRONT AXLE & STEERING

FRONT AXLE & STEERINGFRONT AXLE & STEERING

FRONT AXLE & STEERINGFRONT AXLE & STEERING

FRONT AXLE & STEERING

FRONT AXLE & STEERINGFRONT AXLE & STEERING

STEERINGSTEERING

STEERING

STEERINGSTEERING

Front Axle & Support

Torque Values

Sr No Description Torque (Nm)

1 Front Wheel Nut 65 to 75
2 Rear Wheel Nut 180 to 200
3 Drag link & Tie Rod Nut 35 to 40
4 Steering Ar m Nut 110 to 120
5 Front Axle Support Mounting Bolts 110
6 Pivot Pin Mounting Bolt 21
7 Enine Mounting Bolts to Clutch Housing 45

(Shorter Length)

8 Enine Mounting Bolts to Clutch Housing 60

(Longer Length)

9 Rear Wheel Mounting Bolts 250
10 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 Seat Mounting Bolts 60
17 Steering Gear Box Mounting Bolt 60
18 Check Chain Mounting Bolts 105

Wear Limits

Sr No Description Initial Value Discard Value

(mm) (mm)

1 Front Axle Pivot Pin Bush I.D. 22.06 22.01
2 Pivot Pin To Bush Clearance 0.11 0.01
3 Front Axle Pivot Pin OD 22 21.95
4 Steering Knuckle Pivot shaft OD 25 24.95
5 Steering Knuckle Bush ID 25.06 25.01
6 Steering Knuckle To bush Clearance 0.11 0.01

77

Front Axle & Support

29

28

27

26

25

24

23

22

21

19

13

32

14
15
16

18

14

12

10

11

31

11

3

4

5

30

14

2

4

5

33

1

12

13

9

32

14

15

16

6

8

7

19

20

17

21

24

23

22

25

26

27

29

28

Sr. No. Description

1 Support Front Axle
2 Axle Front Complete
3 washer Thrust Front Axle Support 4.5
4 ‘O’ Ring Pivot Pin Sleeve
5 Bush Pivot Pin Sleeve
6 Pin Pivot Cpte
7 Bolt Pivot Pin
8 Washer Spring Lock

9 Arm Knuckle LH
10 Arm Knuckle RH
1 1 Bolt M12
12 Wahser Spring Lock
1 3 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 Seal Front Wheel Hub
20 Dust Shield
21 Seal Oil Front Wheel Hub
22 Spacer Inner Bearing
23 Bearing Inner Front Wheel Hub
24 Hub Front Wheel
25 Bearing Outer Front Wheel Hub
26 Washer Outer Bearing Retainer
27 Nut Slotted
28 Pin Split
29 Cap Front Wheel Hub
3 0 Nipple Grease
3 0 Nipple Grease
31 Key Wood Ruff
32 ‘O’ Ring King Pin Sleeve
33 Washer Thrust Front Axle Support 2.5

78

General

The Single Piece Front Axle are of box section
steel construction. The axle Pivots on a Pin
which passes through the Front Axle Support
and is retained in position by Lock Plate secured
by lock washer and nut in slot which is
provided on pin. The Pivot Pin Sleeves are
replaceable bushings pressed into the axle.

Removal of Front Axle :
1 ) Support the Engine by Jacks.

2) Remove the 4 Bolts mounting the Front
Axle Support to the engine and separate
the Front Axle Support along with the Front
Axle.

Front Axle & Support

Removal of Steering Arm & Steering Knuckle :

1) Remove the locking bolt of the Knuckle arm,
holding the Knuckle arm with the Steering
knuckle.

2 ) Remove the Knuckle arm over the Key way.

3) Remove the Key and separate the Complete
Steering Knuckle.

Installation :

1 ) Clean all the parts thoroughly and observe

the parts for any cracks, damages etc.

2 ) Oil Seals should be replaced with new ones

during assembly.

3 ) Remove the ‘2’ nos of Locking Bolts on the

Locking Plate holding the Front Axle with
Front Axle Support.

4 ) Remove the locking Plate and remove the

Front Axle Pivot Pin.

5) Separate the Front Axle from the Front Axle
Support.

Dismantling of the Front 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 washer

5 ) Remove the Front tapered roller bearing.

6) Remove the hub.

7 ) From the rear end of the hub, remove the

Inner tapered roller bearing.

3) Assembly is the reverse of dismantling
procedure.

8) Remove the Spacer inner bearing.
9 ) Remove the Oil Seal.

10) Remove dust shield from the Steering
knuckle

11) Remove the V Seal from the Steering
Knuckle.

79

Front Axle & Support

TROUBLE SHOOTING

TROUBLE PROBABLE CAUSE REMEDY

(1) Tractor will not steer. (a) Work or damaged (a) Check drag link, steering

steering linkage, knuckle arms and drop arm

for wear or damage.

(b) Faulty steering gear

assembly .

(2) Tractor is hard to steer. (a) Low tyre pressure. (a) Inflate to specified pressure.

(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 link age, steering knuckle arms for wear

or damage.

(d) Incorrect toe-in. (d) Check and adjust toe-in.

(3) Shimmy (a) Excessive play in front (a) Check for wear or play in

axle and/or steering rocker shaft, drop arm, drag
gear assembly, link, steering knuckles and

pivot pin sleeve.

(b) Incorrect toe-in. (b) Check and adjust toe-in.

80

Steering Assembly

Dismantling procedure of steering gear
box

1 Remove the nut of the drop arm. (Spanner

Size 34)

Drop Arm

Drop Arm

Nut

2 Remove the drop arm by using the puller.

3 Remove the four bolts of the steering

column.

Steering

Column Nut

4 Remove the woodruff key on which the

steering wheel is mounted.

Steering Gear

Drop Arm

Woodruff

Key

Outer Steering

Column

5 Remove the steering column tube.

Tube Steering

Column

Main Steering

Column

81

Steering Assembly

6 Remove the shims.

7 Remove the spacer.

Shims

8 Remove the bearing cage.

Cage

Bearing

9 Remove the nut over the adjusting screw.

82

Spacer

Adjust Screw

Steering Assembly

1 0 Remove the four bolts on the end cover &

remove the end cover. (Adjusting screw
need to rotate to take cover off.)

Mounitng

Bolt

Steering

Gear Cover

11 Adjusting screw need to rotate to take cover

off.

13 Remove the adjuster screw with plain

washer.

Adjuster

Screw

1 4 Remove the worm assembly.

Worm

Assembly

Cover

1 2 Remove the circlip.

Adjusting

Screw

1 5 Remove the main steering column

Main
Steering
Column

Circlip

83

Steering Assembly

1 6 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.

84

85