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
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