H1 Service Manual93 PDF

Foreword
We are pleased to present the ‘Service Manual’ for ‘Mahindra Tractors’
Efforts have been made to provide all relevant details like specifications, dismantling, assembly, cleaning,
repairs, adjustments & trouble shooting. To make the understanding of the product easier, pictorial &
exploded views of parts & aggregates have been incorporated in this manual.
It is suggested to use special service tools & genuine parts to get best of service in terms of timeliness,
product performance & reliability.
We hope you will find the Service Manual very useful. We request you to let us know your suggestions
if any.
Customer Care Department

Mahindra & Mahindra Ltd.
Mahindra Towers,
Dr. G.M. Bhosale Marg.,
P. K. Kurne Chowk,
Worli, Mumbai - 18
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INDEX
SECTION DESCRIPTION PAGE

Group 1 - General 01-08
Introduction 02-03
Safety Notes 04-04
Specifications for Mahindra Tractors 05-08
Group 2 - Engine 09-66

Chapter 1 - Introduction 11-18
Chapter 2 - Manifolds, Cylinder Head & Valves 19-27
Chapter 3 - Connecting Rods, Pistons & Cylinder Sleeves 28-35
Chapter 4 - Lubrication System 36-41
Chapter 5 - Timing Gear Train, Front Cover & Camshaft 42-46
Chapter 6 - Crankcase, Crankshaft, Main Bearings & Flywheel 47-56
Chapter 7 - Turbo Charger 57-60
Engine Tune-UP 61-61
Trouble Shooting 62-66
Group 3 - Air Cleaner & Fuel System 67-106

Chapter 1 - Air Cleaner 68-70
Chapter 2 - Fuel System 71-78
Chapter 3 - Rotary Fuel Injection Pump 79-86
Chapter 4 - Fuel Injection Pump Calibration Chart 87-106
Group 4 - Cooling System 107-118

Group 5 - Clutch 119-138
Single Plate Coil 122-127
Single & Dual Plate Diapraghm 128-137
Trouble Shooting 138-138
Group 6 - Transmission 139-184

Chapter 1 - Sliding & Partial Constant Mesh 141-162
Chapter 2 - Differential 163-174
Chapter 3 - Power Take offs (Standard & C.R.P.T.O.) 175-184
Group 7 - Axle & Wheels 185-198

Three Piece Adjustable Front Axle 187-195
Single Piece Front Axle 196-198
Group 8 - Brakes 199-210

Chapter 1 - Mechanical Brakes 200-205
Chapter 2 - Lubritech (Oil Immersed Brakes) 206-210
Group 9 - Steering 211-220

Group 10 - Instruments, Gauges & Electricals 221-232
Group 11 - Hy-Tec Hydraulics 233-266
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GROUP - 1
General
Introduction
Safety Notes
Specifications for Mahindra Tractors
1st Version 1st set.pmd 1 6/3/2006, 11:20 AM

General
A. INTRODUCTION should be used over splines and threads

A-1 General before sliding on oil seals or ‘O’ Rings.
2 The instructions contained in this manual are 2. All expansion and cap plugs are to be
for the information and guidance of assembled with sealer. All pipe plugs
servicemen responsible for the repair and permanently installed are to be
overhaul of Mahindra Diesel tractors. assembled with sealer. No sealer should
This manual provide the serviceman with be used on plugs which have to be
comprehensive information on operation, removed for routine servicing.
maintenance and repair of the engine, chassis 3. Cork, fibre and felt gaskets may be
and hydraulic systems of the tractor. assembled with jointing compound.
Throughout this manual the terms LEFT, A-5 Service Tools
RIGHT, FRONT and REAR are to be taken Few special tools are required for repairs /
as those applicable to a person seated in the
overhaul of tractor Mahindra supplies the
driver’s seat and facing the radiator of the
required special tools and instructions to use
tractor.
the tools. Use of these tools will enhance
A-2 Cleanliness productivity and repair quality.
The utmost care must be taken to prevent A-6 Service Parts
dirt entering any part of the tractor,
Years of experience in the design and
particularly the fuel and hydraulic systems.
manufacture of tractors has given Mahindra
Before removing any fitting or assembly, the
the ability to produce quality which will not
area around it should be cleaned and blown
be found in imitation or ‘will fit’ parts. As a
dry, with compressed air. As soon as any
good serviceman you cannot afford the risk
pipe is removed, it should be capped and
of your reputation that the use of these parts
the port into which connection was made
will bring. No serviceman can guarantee a
should be corked or covered with masking
repair job where genuine parts are not used
tape. Before undertaking a major overhaul
and no customer should be satisfied with
the tractor should be washed and allowed
anything other than genuine parts.
to dry.
For the correct parts to be used, always
A-3 Lubrication
refer to the Parts Catalogue for the particular
Instructions for the routine lubrication of the machine. Reference must always be made
tractor is given in the “Operators Manual”. to the machine and engine serial number
All lubricants in storage should be in clean when servicing a machine.
containers. When assembling any parts, coat
NOTE : Warranty does not cover the use of non-
all wearing surfaces with the appropriate
Mahindra sourced parts.
lubricant. Use sufficient quantity of lubricant
to prevent seizing, scoring or excessive wear A-7 Serial Numbers
during the initial running period after Engine and Tractor Serial Numbers can be
reassembly. readily located on tractors. The engine
NOTE : FAILURE TO PROVIDE “STARTING number is stamped on crankcase RH side
LUBRICATION” MAY RESULT IN SERIOUS and Tractor serial number plate is fitted on
DAMAGE the battery box. While ordering the spare
parts always mention the Tractor serial
• Taper pins must be installed dry.
number.
• NEVER SMEAR OR DIP GASKETS IN
OIL. A-8 Where adjustments are necessary the
respective group will contain the relevant
A-4 Gaskets, Seals and Plugs
Information. Reference to that section before
1. Oil seal lips should generally be coated commencing to dismantle the unit may
with oil before assembly with keeping prevent unnecessary work being carried out.
the lip toward the chamber in which the
Please read the below contents carefully before
oil is contained. Any exception to this
attempting to read the manual further.
will be mentioned in the text. A sleeve

General
A-9 Illustration Reference B-5 Welds

Four types of illustration reference will be Check all welded assemblies for cracks, twisting
found in this manual, and these are and misalignment. Information concerning the 3
explained by the following example :- use of special welding rods or welding procedure
I) (1-4) This refers to the item marked by indicator is detailed, where relevant, in the appropriate
number 1 in figure 4 of the group in which the section of the group.
reference appears. B-6 Castings
II) (1 & 2-4) This refers to the items marked by Check castings for cracks and distortion.
indicator number 1 & 2 in figure 4 of the group B-7 Fuel Tanks
in which the reference appears.
Check for leaks and internal corrosion.
III) (1-4 & 2-6) This refers to the items marked by
B-8 Fuel, Oil and Coolant Pipes and Hoses
indicator number 1 in figure 4 & indicator number
2 in figure 6 in the group in which the reference Check unions for leaks, stripped threads or other
appears. faults. Check pipes for cracks or chafing, hoses
for chafing, twisting or other damage.
IV) The indicator of this nature appearing at any
place will mean that the reader should refer to B-9 Lubrication Fittings
Item No. 1 of figure No. 4 from Engine Group. Check for damage of missing fittings and
V) A group name may be also used in conjunction replace. Check that grease and oil galleries are
with (a), (b) or (c) to indicate the indicator number, clear.
figure number and group which the illustration B-10 Gaskets & Seals
appears. For be extremely careful not to damage seals or
gaskets during installation. Pack lip type seals
B. INSPECTION & REPAIR with grease and use sleeve when a seal has to
be passed over splines or threads.
The following notes should be used as a general
guide to inspection and repair. Where a special
procedure is necessary for a component or Always use new gaskets seals, cotter pins during
assembly, full details will be found in the relevant assembly.
section of the group. NOTE : Never smear or dip gaskets in oil before
B-1 Bearings assembly
Inspect for evidence of overheating, cracks,
scores, pitting and general wear. Replace if
necessary. Soack in oil, wrap and cover with
grease proof paper until required for assembly.
B-2 Pins & Bushes
Inspect for damage, scoring and pitting, check
with mating parts for wear. Replace if necessary.
B-3 Clevis, Clevis Pins and Circlips
Check with mating parts for wear. It is usually
advisable to replace such pins/circlips while
overhauling.
B-4 Gears & Spline
Check for cracks, pitting, burns, broken chipped
teeth. Check for excessive wear with mating
parts. Dress off burns from gears and splines with
a fine carborundum stone; care must be taken to
remove the burr only. DO NOT interfere with the
tooth or spline profile. REPLACE all parts which
show signs of damage or excessive wear.

General
SAFETY NOTES
4
SAFETY - ALERT SYMBOL AND TERMS
This Safety Alert Symbol means ATTENTION! The safety alert symbol identifies important
BECOME ALERT! YOUR SAFETY IS IN- safety messages on machines, safety signs,
VOLVED! is manuals, or elsewhere. When you see this
symbol, be alert to the possibility of personal
injury or death. Follow the instructions in the
safety message.
Why is SAFETY important to you?

# ACCIDENTS DISABLE AND KILL
# ACCIDENTS ARE COSTLY
# ACCIDENTS CAN BE AVOIDED
Remember that YOU are the key to safety. Good Work Safely – Follow these Rules
safety practices not only protect you, but also the 1. Always wear safety glasses when using a
people around you. Study the features in this manual hammer, chisel or other tools that may cause
and make them a working part of your safety chips to fly.
program. Keep in mind that this safety section is 2. Keep work area organized and clean. Wipe up
written only for this type of machine. Practice all other oil or spills of any kind. Keep tools and parts off
usual and customary safe working precautions, and of the floor. Eliminate the possibility of a fall which
above all - REMEMBER - SAFETY IS YOUR could result in a serious injury.
RESPONSIBILITY. YOU CAN PREVENT SERIOUS 3. Be sure to reinstall safety devices, guards or
INJURY OF DEATH. shields after adjusting and/or servicing the
machine.
SAFETY - DANGER, WARNING and CAUTION
4. After servicing, be sure all tools, parts, or
Whenever you see the words and symbols shown servicing equipment are removed from the
below, used in this book and on decals, you MUST machine.
take note of their instructions. 5. Use a safety catch on all hoist hooks. Do not take
a chance, the load could slip off the hook.
DANGER : The symbol and the word 6. Electrical storage batteries give off explosive
DANGER indicates an imminently hazardous situation hydrogen gas when charging and continue to do
with, if not avoided, will result in DEATH OR so for some time after receiving a steady charge.
Do not under any circumstances allow an electric
SERIOUS INJURY. spark or an open flame near the battery. Always
disconnect a battery cable before working on the
electrical system. Always wear safety goggles
WARNING : The symbol and the word when servicing batteries.
WARNING indicates a potentially hazardous situation. 7. Use proper tools to make repairs, using hammers
If the instructions or procedures are not correctly and chisels or punches when pullers should be
followed it could result in PERSONAL INJURY, OR used increases the probability of injury.
LOSS OF LIFE. 8. Be careful when using compressed air to dry
parts. Use approved air blow guns, do not exceed
30 psi, wear safety glass or goggles and use
CAUTION : The symbol and the word proper shielding to protect everyone in the work
CAUTION identifies special instructions or procedure area.
which if not strictly observed, could result in 9. Do not wear rings, wrist watches or loose fitting
DAMAGE, DESTRUCTION OF EQUIPMENT, OR clothing when working on machinery because
PERSONAL INJURY. they could catch on moving parts causing serious
injury. Wear sturdy, rough-soled work shoes.
Never adjust and/or service a machine with bare
NOTE : The word NOTE indicates points of particular feet or while wearing sandals or sneakers.
interest for more efficient convenient repair
or operation.

General
SPECIFICATIONS FOR MAHINDRA TRACTORS

Specifications of Mahindra Tractors
595 DI 585 DI 575 DI 475 DI B275 DI B275 DI 365 DI 265 DI 255 DI 5
Super Turbo (TU Series)
ENGINE
Type MDI 3000TC MDI 3000-B MDI 2500 MDI 2385 MDI 1895 B MDI 1895 MDI 1815 MDI 1785 MDI 1250 A
No. of Cylinders 4 4 4 4 3 3 3 3 2
Bore / Stroke mm 88.9/101.6 88.9/101.6 88.9/101.6 88.9/96 88.9/101.6 88.9/101.6 88.9/97.2 88.9/96 88.9/110.0
Displacement cc 2523 2523 2523 2384 1891 1891 1810 1788 1366
Rated Governed Speed 2100 2600 2300 2300 2600 2300 2300 2300 2400
Low Idle R.P.M 825 ± 25 825 - 875 700 ± 50 700 ± 50 850 ± 25 700 ± 50 700 ± 50 700 ± 50 850 ± 25
High Idle R.P.M 2300 ± 25 2800 ± 50 2500 ± 50 2500 ± 50 2800 ± 50 2500 ± 50 2500 ± 50 2500 ± 50 2640 ± 50
Valve Clearance Hot - Inlet 0.3, Exhaust 0.4 • Cold - Inlet 0.4, Exhaust 0.5
Air Cleaner Dry Type Three stage oil bath with paper element
Nozzle Injection Pressure 250+8 kg/sq.cm 200 ± 10 kg / sq.cm
COOLING SYSTEM Water cooled pressurised, Operating pressure - 0.8-0.9 Kg/Sq.cm, Thermostat operating temperature - 74 to 82O C
CLUTCH Standard - 11” Single dry driven plate, Optional - Dual clutch with 11” clutch driven plates only on 595DI, 585 DI, 575 DI & 475 DI models
TRANSMISSION 8 Forward and 2 Reverse speeds with High-low selector lever
Type Constant Mesh Constant Mesh Constant / Constant* / Sliding Mesh Sliding Mesh Sliding Mesh Sliding Mesh Sliding Mesh
Sliding Mesh Sliding Mesh
POWER TAKE OFF Rear mounted with six spines, Constant running - 540 r.p.m.
Standard PTO rpm
at rated engine speed 627 709 627 627 709 627 627 627 654
STEERING Recirculating ball or worm & peg or worm & roller
BRAKES Totally enclosed self energising dry disc with heavy duty friction liners. Optional lubritech brakes (oil immersed brakes)#
HYDRAULIC SYSTEM Hytech Hydraulics. Fully live Hydraulic with Position & Draft Controls
Lifting Capacity 1800kgs 1640 kgs 1640 kgs 1000 kgs 1000 kgs 1000 kgs 1000 kgs 1000 kgs 1000 kgs
TYRES Standard Front 6.00 x 16 6.00 x 16 6.00 x 16 6.00 x 16 6.00 x 16 6.00 x 16 6.00 x 16 6.00 x 16 6.00 x 16
Rear 13.6 x 28 13.6 x 28 13.6 x 28 12.4 x 28 12.4 x 28 12.4 x 28 12.4 x 28 12.4 x 28 12.4 x 28
Optional Front 7.5 x 16 7.5 x 16
Rear 16.9 x 28 16.9 x 28
OPERATING WEIGHT &
DISTRIBUTION (kgs)
Front 755 763 751 693 694 694 694 694 633
Rear 1215 1165 1141 1140 1051 1051 1051 1051 1073
Total 1970 1928 1892 1833 1745 1745 1745 1745 1706
CAPACITIES (Litres)
Engine (including filter) 9.5 7.6 7.6 7.6 5.5 5.5 5.5 5.5 4.75
Cooling System (Approx) 7.95 7 7 7 5.5 5.5 5.5 5.5 4
Steering Gear Box 0.93 0.5-0.84 0.5-0.84 0.5-0.84 0.5-0.84 0.5-0.84 0.5-0.84 0.5-0.84 0.5-0.84
Fuel Tank 55 48 - 55 48 - 55 48 - 55 48 - 55 48 - 55 48 - 55 48 - 55 48 - 55
Transmission System 24/29 § 23.5/28.5 § 23.5/28.5 § 23.5/28.5 § 23.5 23.5 23.5 23.5 23.5
Trans. System (For OIB#) 35 35
Air Cleaner 0.0 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5
Hydraulic System 11.5 + 2 ♦ 11.5 11.5 11.5 11.5 11.5 11.5 11.5 11.5
DIMENSIONS (In mm)
Overall Height 2180 2040 2180 2020 2030 2030 2030 2030 2060
Overall Length 3180 3135 3180 3065 3096 3096 3096 3096 3078
Ground Clearance 372 372 390 345 367 367 367 367 376
Overall Width 1782 1755 1782 1625 1665 1665 1665 1665 1661
Wheel Base 1945 1925 1910 1910 1838 1838 1838 1838 1822
* — 475 DI Sarpanch model is provided with Constant Mesh Gear Box. Bhoomiputra model is provided with sliding mesh gear box.
♦ — For tipping trolley applications. § — In case of CRPTO.
# — Lubritech Brakes (Oil Immersed Brakes) - Optional only in 575 DI, 475 DI, Sarpanch Series with New Sheet Metal.
(All dimensions and specifications for guidance only & are subjected to change without prior notice)

General
6
Wheel Base
Overall Height
Overall Width
Ground
Clearance
Overall Length
* — 475 DI Sarpanch model is provided with Constant Mesh Gear Box. Bhoomiputra model is provided with sliding mesh gear box.
§ — in case of CRPTO.
# — Lubritech Brakes (Oil Immersed Brakes) - Optional only in 575 DI, 475 DI, Sarpanch Series with New Sheet Metal.
(All dimensions and specifications for guidance only & are subjected to change without prior notice)

General - Lubrication & Greasing (Chart)

General
Notes :

GROUP - 2
Engine
Chapter 1 - Introduction
Chapter 2 - Manifolds, Cylinder Head & Valves
Chapter 3 - Connecting Rods, Pistons & Cylinder Sleeves
Chapter 4 - Lubrication System
Chapter 5 - Timing Gear Train, Front Cover & Camshaft
Chapter 6 - Crankcase, Crankshaft, Main Bearings & Flywheel
Chapter 7 - Turbo Charger
Engine Tune-UP
Trouble Shooting

Engine - DI Engine (Chart)
10

Engine - Introduction
11
Chapter-1 Introduction
General
Engine Removal & Installation
Engine Specifications

A. GENERAL 4. Unclip the main cable harness from the bottom

Mahindra Tractors have 2, 3 or 4 cylinder direct of the radiator.
injection water cooled diesel engines with inline 5. Disconnect head lamp and horn cable.
fuel injection pumps and overhead valves. These 6. Remove the hood pivot bolts and remove the
engines have superior specific fuel consumption hood.
with very low smoke emission and very low
7. Drain the coolant.
crankcase oil dilution.
12 8. Disconnect the radiator brace and fan shroud from
1. ENGINE radiator.
1a. Removal : 9. Loose hose clips and remove inlet and outlet
1. Use MST-H1/2-MP-1 special service tool for hose pipes of the radiator.
removal of engine (fig-1) as follows : 10. Remove the two nuts from the bolts securing the
Keep the rail under the tractor (fig-2). radiator to the front axle support. Lift the radiator
Place jack & support of engine below oil sump. and rubber pads off. Place the wooden block
Place minin jacks between front axle & front axle between axle and axle support prevent tilting.
support & lock to avoid swinging of engine. 11. Lock the brakes and securely block the rear
Place transmission jack below transmission case wheels.
rectangular part. 12. Disconnect the drag link.
Raise the jacks till they bear the load . 13. Support the front of the tractor to take most of
2. Remove the vertical exhaust silencer, pre-cleaner the weight off the front tires. Unbolt the radius
and raise the hood. arm bracket fit. (1-4) from the clutch housing.
3. Disconnect the battery earth cable before 14. Remove the front support securing 4 cap screws
disconnecting any electrical system. from both sides. Raise tractor engine until crank
shaft pulley will clear support then roll out front
axle support with front axle and tyres.
NOTE : Take care to keep the Front Axle assembly
vertical once it has been withdrawn from the
engine other wise it could over balance and
cause injury.
15. Disconnect the generator / alternator leads, the
oil pressure pipe, and release the harness from
the securing clips situated around the front of the
engine.
16. Disconnect the starter motor supply cable,
solenoid wire and main harness feed wire from
the starter (2-4).
Fig. 1
17. Disconnect the high and low pressure pipes
(1-3). at the Hydraulic pump removing two socket
head cap screws on each connection
18. Remove the heat indicator sensor from the head.
19. Disconnect the engine stop control rod/cable and
governor control rod at the fuel pump.
20. Remove the fuel feed pipe from fuel injection
pump and close the fuel-shut-off tap and
disconnect fuel supply line.
21. Disconnect the hour meter cable by removing to
cap screws.
Fig. 2

1 2c. INSTALLATION OF ENGINE :

1. Install the clutch driven disc by passing
clutch centraliser cum finger setting tool
MST-H1-TN-4 (fig-5) through the drive member and
insert spigot end into the pilot bearing. Place the
“flywheel” side toward the flywheel.
2. Place the drive disc (flywheel side mark toward
13
the flywheel) and clutch cover assembly over the
aligning tool. Line up the dowel holes in the
cover over the dowels in the flywheel. Insert the
six bolts and lock washer and tighten up evenly.
Withdraw the aligning tool.
NOTE : It is recommend that new gaskets and
Fig. 3 ‘O’ Rings be used on installation.
3. Sling the engine securely. Hoist the engine into

position in front of the clutch housing and enter
the transmission drive shaft into the clutch
assembly.
4. Move engine back turning the transmission and
P.T.O. drive shaft to engage the splines of the
clutch driven members, until the shaft is located
in the pilot bearing and the clutch housing is
located on the crankcase dowels.
NOTE : When engine is removed from tractor.
Chassis for overhauling always take out the
starter motor the alternator & the hydraulic
pump and send them for testing.
5. Insert, and tighten the attaching bolts.
2 1 Fig. 4
NOTE : To assist assembly, two longer bolts may be
22. Remove the cap screws and lock washer securing used to guide and to draw the engine upto
the flywheel dust cover. the clutch housing.
23. Sling the engine securely and with a suitable hoist 6. Installation is now the reversal of the removal
tension the sling. procedure by using new parts with kit.
24. Remove the 7 cap screws and attaching the 7. Fill the cooling system and check the air cleaner
engine to the clutch housing. oil, engine oil, hydraulic oil, fuel and then bleed
the diesel fuel system.
25. Ease the engine away from the clutch housing.
Take care that the transmission drive shaft is NOTE : When rejoining engine to clutch housing,
time can often be saved, particularly on duel
withdrawn squarely from the pilot bearing and
clutch models if the following procedure is
clutch assembly.
used. Unbolt clutch assembly from flywheel
and place same on transmission input shaft.
Move section together until clutch (input)
shaft pilot enters pilot bearing and flywheel
butts against clutch cover.
Now bolt clutch to flywheel and complete
matching of engine and clutch housing by
pulling sections together with retaining cap
screw.
Fig. 5

Engine Specifications
1. GENERAL
595 DI 585 DI 575 DI 475 DI B275 DI B275 DI 365 DI 265 DI 255 DI
Super Turbo (TU Series)
ENGINE
Type MDI 3000TC MDI 3000-B MDI 2500 MDI 2385 MDI 1895 B MDI 1895 MDI 1815 MDI 1785 MDI 1250 A
14
No. of Cylinders 4 4 4 4 3 3 3 3 2
Bore / Stroke mm 88.9/101.6 88.9/101.6 88.9/101.6 88.9/96 88.9/101.6 88.9/101.6 88.9/97.2 88.9/96 88.9/110.0
Displacement cc 2523 2523 2523 2384 1891 1891 1810 1788 1366
Rated Governed Speed 2100 2600 2300 2300 2600 2300 2300 2300 2400
Low Idle R.P.M 825 ± 25 825 - 875 700 ± 50 700 ± 50 850 ± 25 700 ± 50 700 ± 50 700 ± 50 850 ± 25
High Idle R.P.M 2300 ± 25 2800 ± 50 2500 ± 50 2500 ± 50 2800 ± 50 2500 ± 50 2500 ± 50 2500 ± 50 2640 ± 50
2. MANIFOLDS, CYLINDER HEAD & VALVES

INLET VALVES (No.) For 4 cyld. engine-4, For 3 cyld. engine-3, For 2 cyld. engine-2
Stem diameter (mm) 8.7 / 8.6
Port diameter (mm) 33.27
Head diameter (mm) 38.7 / 38.2
Clearance in guide (mm) 0.05 / 0.02
Valve face angle (deg) 450 / 44044'
Valve seat angle (deg) 450 / 44030'
EXHAUST VALVES (No.) For 4 cyld. engine-4, For 3 cyld. engine-3, For 2 cyld. engine-2
Stem diameter (mm) 8.68 / 8.66
Port diameter (mm) 26
Head diameter (mm) 36 / 35.8
Clearance in guide (mm) 0.08 / 0.05
Valve face angle (deg) 450 / 44040'
Valve seat angle (deg) 450 / 44030'
Tappet clearance Hot (mm) 0.4
Tappet clearance Cold (mm) 0.3
VALVE GUIDES (No.) For 4 cyld. engine-8, For 3 cyld. engine-6, For 2 cyld. engine-4
Length - Inlet (mm) 60
Length - Exhaust (mm) 60
Inside diameter (mm) 8.8 / 8.7
Set height of guide measured from Cylinder Head Topdeck
Height - Inlet (mm) 1.98
Height - Exhaust (mm) 1.98
VALVE SPRINGS
Test length (mm) 41.98
Test load (kg) 4.27
Final length (mm) 31.97
Final load (kg) 31.56
Free length (mm) 50.4
Spring rate (at 30-70% of finest load) (mm) 2457.7
VALVE LEVERS, SHAFT AND BRACKETS

Shaft diameter (mm) 21.97 / 21.94
Running clearance (mm) 0.08 / 0.02
Bushing I.D. (mm) 22.02 / 21.99
Brackets bore (mm) 22.02 / 21.99
VALVE TAPPETS (No.) Two per cylinder
Deameter (mm) 14.22 / 13.97
Running clearance (mm) 0.013 / 0.076
VALVE PUSH RODS (No.) Two per cylinder

Diameter (mm) 7.95

Length (mm) 248.3
VALVE TIMING
Inlet opens (deg. BTDC) 90
Inlet closes (deg. ABDC) 350
Exhaust opens (deg. BBDC) 420
Exhaust closes (deg. ATDC) 100
3. CONNECTING RODS, PISTONS AND CYLINDER SLEEVES

15
CONNECTING RODS
Material Forged steel
Bearing (big end) type Replaceable, shell
Meterial Steel backed babbit
Piston pin bush ID Same as small end bearings
Small end (bearings) Replaced
Type Bush
Material Bronze
Small end bush diameter (mm) 28 / 28
PISTON RINGS
Number of Rings per piston (No.) 3
Top Key stone, crome plated
Middle Bevelled
Bottom Oil scraper
Width (Axial)
Top (mm) NA - Keystone ring
Middle (mm) 2.5 / 2.47
Bottom (mm) 3.98 / 3.96
Ring Gap
Top (mm) 0.46 / 0.25
Middle (mm) 0.43
Bottom (mm) 0.89
PISTONS
Type Cam ground oval.
Material Aluminium Alloy
Graded The weight of the piston is punched on the Top face.
In one engine the weight difference between any two
should not be more than 5gms.
Cavity Volume (CC) 26.3 cc
Dia at crown 3.485
Dia at skirt 3.496
Dia at just below oil control ring 3.494
Piston to cylinder clearance
at skirt 900 from piston pin hole (mm) 0.10
Piston Pin boss bore (mm) 28 / 28
Number of Ring Groove (No.) 3
width of ring groove (mm)
Top Groove NA - Keystone taper
Middle Groove (mm) 2.57 / 2.55
Bottom Groove (mm) 4/4
Clearance in grooves
Top groove —
Middle groove (mm) 0.09 / 0.05
Bottom groove (mm) 0.07 / 0.03
PISTON PINS
Diameter (mm) 27.99 / 27.99
Standard
Oversize-marked +5 (mm) 28
Clearance in piston (mm) 0.01 / 0.002
Clearance in con rod (mm) 0.03 / 0.02
Length (mm) 66.8 / 66

CYLINDER SLEEVES
Type Replaceable wet liner
Material cast iron
Wall thickness (mm) 5.30
Sleeve O.D. (mm) 99.61 / 99.36
Sleeve I.D. (mm) 88.91 / 88.9
Flange stand out (mm) 0.05 above face to 0.03 below face
Flange width (mm) 5.71 / 5.69
16 Max. taper (mm) 0.01
Max. ovality (mm) 0.01
Sleave I.D. Discard limit (mm) 88.97 and above
4. LUBRICATION SYSTEM
PRESSURE REGULATING VALVE

Location Oil pump body
Spring free length (mm) 65
Spring test length (mm) 44
Spring test load (kg) 7 ± 3%
Opening pressure (kg/cm2) 2.11 to 2.46
Valve clearance in bore (mm) 0.03 / 0.07
BY-PASS VALVE
Location Filter Head
Opening pressure (kg/cm2) 0.87/ 1.30
OIL PUMP Internal rotor camshaft drivers

Backlash
Idler to body grars (mm) 0.08/ 0.20
Drive pinion to camshaft (mm) 0.20 / 0.30
Clearances
Gears to housing (mm) 0.13 / 0.21
Gears to end plate (mm) 0.09 / 0.15
Drive shaft to body (mm) 0.04 / 0.09
Drive pinion to body (mm) 0.05 / 0.10
5. COOLING SYSTEM
Type Water cool, force feed
WATER PUMP TYPE Centrifugal

Clearances Flush
Body face to impellor face 0.001 interferance
Bearing shaft to impellor bore 0.001 interferance
Bearing shaft to pulley hub bore 0.003
Bearing to pump body 0.0008 interferance
THERMOSTAT
Range (0C) 74 - 820C
6. TIMING GEAR TRAIN, FRONT COVER AND CAMSHAFT
CAMSHAFT
Material Chilled cast iron
Number of bearings (No.) 3
Bearing journal diameter
Front (mm) 46.78/46.76
Centre (mm) 46/45.99
Rear (mm) 38/37.84

Bearing bushing diameter
Front (mm) 46.84/46.8
Centre (mm) 46/46
Rear (mm) 38/38
Running clearance (mm) 0.09/0.04
Exhaust cam lift (mm) 6.32
Inlet cam lift (mm) 6.27
Max cam shaft lobe
Wear (mm) 0.5 17
End clearance (mm) 0.43/0.20
TIMING GEARS
Number of teeth
Crankshaft gear (No.) 33
Camshaft gear (No.) 66
Injection pump gear (No.) 66
Idler gear (No.) 46
Backlash between any pair of gear (mm) 0.18/0.06

Idler gear end clearance (mm) 0.3/0.127
Idler gear end float (mm) 0.127/0.03
7. CRANKSHAFT
CRANKSHAFT
Material Alloy steel
Main journal diameter (mm) 58/58
Running clearance main journal (mm) 0.08/0.02
Crank-pin diameter (mm) 44.47/44.45
(2.2972/2.290 for 5005 DI)
End clearance (float) (mm) 0.2/0.1
Side clearance main journal (mm) 0.2/0.1
Running clearance crank pin (mm) 0.08/0.02
Side clearance crank pin (mm) 0.02/0.08
Rear end oil seal dia. (mm) 91.99
MAIN BEARINGS
Type Replaceable, shell
Material Steel backed babbit

TORQUE LOADING (TIGHTENING TORQUE) CHART
1. Cylinder head bolts (Nm) 81 - 88

2. Connecting rod bolts (Nm) 47 - 54
3. Crankshaft main bearing caps
New cap / New bolt (Nm) 128.8 - 135
Old cap / Old bolt (Nm) 108 - 115
Old cap / New bolt (Nm) 108 - 115
18 4. Rear oil seal retainer bolt (Nm) 36 - 42
5. Idler gear shaft bolt (Nm) 101
6. Nozzle body stud (Nm) 40 - 47
7. Nozzle body nut to stud (Nm) 21 - 27
8. Flywheel bolt (Nm) 88 - 94
9. Adapter spigot fixing nut (Nm) 58 - 67
10. Tappet adjusting nut (Nm) 27 - 33
11. Valve housing cover nut (Nm) 27 - 33
12. Crankcase drain plug (Nm) 47 - 54
13. Camshaft thrust plate (Nm) 47 - 54
14. Front pulley nut (Nm) 305 - 339
15. Starter motor bolts (Nm) 47 - 54
16. Injection pump bolt (Nm) 25 - 28
17. Injection pump gear bolt (Nm) 25 - 28
18. Rocker arm center bracket (Nm) 81 - 88
19. Rocker arm end brackets (Nm) 40 - 50
20. Generator pulley nut (Nm) 34 - 40
WEAR LIMITS
Cylinder sleeves
Bore diameter (mm) 89.13
Ovality (mm) 0.013
Taper (mm) 0.013
Piston rings
Ring gap
First ring (mm) 2.5
Second ring (mm) 2.5
Third ring (mm) 2.0
Valve train
Valve guide clearance (mm) 0.2
Tappet valve clearance (mm) 0.2
Spring rate (Kg/mm) 1.4
Crankshaft
Main bearing clearance (mm) 0.2
End play (mm) 0.6
Connecting rod
Big end bearing clearance (mm) 0.2
End play (mm) 0.75
Camshaft
Bearing clearance (mm) 0.2
End play (mm) 0.43
Cam lobe wear (mm) 0.508

Engine - Manifolds, Cylinder Head & Valves
19
Chapter-2 Manifolds, Cylinder Head & Valves

Description
Manifold Removal
Cleaning, Inspection & Repairs
Installation
Tips for Service of Cylinder Head

1. DESCRIPTION 3. VALVE ROCKER ARM SHAFT ASSEMBLY

1a. MANIFOLDS 3a. REMOVAL :
Two manifolds are used on diesel engines. The Thoroughly clean the engine externally.
intake manifold being bolted to left side of the cylinder a) Remove the two nuts (4-1).
head and the exhaust manifold being bolted to the
Clamps/stiffner and rubber washer. Then
right hand side.
remove the valve housing cover and the
20 gasket.
1b. CYLINDER HEAD AND VALVES b) Remove the two nut from studs (1-3) from
The cylinder head is cast in one piece and houses the outer valve lever shaft bracket. Which
the intake and exhaust valves. hold the valve lever shaft brackets cylinder
NOTE : In this valves are arranged in sequence of head.
For 4 cylinder engine inlet valve first then c) Remove the bolt (3-3) from the centre (long
inlet, inlet exhaust, exhaust, inlet. valve lever bracket.
For 3 cylinder exhaust valve first then, inlet,
inlet exhaust, exhaust, inlet.
Replaceable valve seat inserts are provided for
cylinder head serviceability. 4 2
1
2. MANIFOLDS
2a. REMOVAL :
1. Intake Manifold Removal :
a) Drain and remove the power steering 3
reservoir if it is fitted.
b) Remove the fuel filters, (1-1).
c) Remove the injector lines, (2-1).
d) Remove the manifold bolts and lift it off, (3-1).
e) Exhaust manifold can be removed by
removing the four bolts (1-2).
2. Exhaust Manifold Removal :

a) Remove the manifold bolts & manifold.
2b. INSTALLATION :
a) Reverse the removal procedure.
b) It is always advisable to replace the Inlet &
exhaust manifold gaskets with new ones.
c) Torque the mounting bolts at the specified
torque to avoid leakage of gases. Fig. 1
2c. CLEANING, INSPECTION & REPAIR

Clean the manifold and inspect for cracks and
distortion. Replace the manifold with New one,
whenever distortion is more than 0.4 mm per 250mm
length. Inspect Air Hose & Clamps. Inspect retainer
bolts and their washers, replace damage parts.

1 NOTE : Replace worn screw & nut with new

ones.
f) Check expansion plugs on both ends of the

lever shaft for leakage and replace plugs,
if necessary, using sealer.
g) Check valve lever springs against
specifications and replace with new ones if 21
signs of corrosion chafing or fatigue show.
3d. ASSEMBLY :
Engine valve rocker arm (Ref. Fig .7).
a) Position the shaft in the center bracket
ensuring that the oil hole in the shaft
Fig. 2 towards the bottom of the bracket. Secure it
d) Lift of the valve rocker arm shaft and with a new groove pin.
brackets.
e) Lift out the push rods marking them so that 6
they may be returned to their original
positions. 1
7
3
B. DISMANTLING :
3b. ROCKER ARM SHAFT
a) Remove circlip from both ends of the shaft
2
and take out Rocker Arms and other parts
b) To shift from centre bracket remove the roll
pin and remove the shaft. Identify the rocker
arms so that it can be installed in their original
position.
Fig. 3
3c. INSPECTION & REPAIRS
a) Thoroughly clean all components in Kerosene
or Diesel and blow using compressed air.
Be sure all oil passages are free from sludge
and sediment.
b) Check the valve lever shaft expansion plugs.
c) Check the clearance between the valve rocker
arm shaft and valve rocker arm bushings.
d) Check the valve lever bracket for wear in the
bore.
e) Replace valve rocker arms that show
excessive wear of hammering at the ends
(2-3) which contact the valve, remove only
enough material to give an even face on the
end of the valve lever and take care that the
rounding is maintained lengthwise to ensure
perfect grinding action on valve stem.

3f. ADJUSTMENTS :
a) Tappet clearance must be set after the
cylinder head cap screws have been
tightened to the correct torque.
Front
side b) Move each piston in the firing order to top
dead center on the compression stroke. This
Tightening sequence for 4 Cylinder Engines can be ascertained by watching the valves
22
of No.4 cylinder until intake valve just
beginning to open and exhaust valve is just
closing. No. 1 piston is now at T.D.C. on
compression stroke.
c) Slacken off the valve adjusting screw
Front
side locknuts and turn the screw until to the
specified clearance (inlet 0.25mm, exhaust
0.30mm) feeler gauge is just snug fit
between the end of the valve stem and the
Tightening sequence for 3 Cylinder Engines
valve lever. Tappet clearance while in hot,
inlet 0.3mm and exhaust 0.4mm.
d) Hold the screw in this position and tighten
the locknut.
e) Similarly adjust the valve clearance of the
Front
side
remaining cylinder in firing order by bringing
each piston to top dead center on the
compression stroke in sequence.
Tightening sequence for 2 Cylinder Engines

4. CYLINDER HEAD
Fig 4
4a. REMOVAL
b) Assemble rocker arm spacer, rocker arm,
1) Remove the manifolds as detailed earlier.
spring rocker arm bracket, rocker arm to the
shaft and secure them with a washer and 2) Remove the valve rocker arm shaft
retaining ring. assembly as detailed earlier in para 3a.
3) Remove the push rods and identify them so
they can be installed in their original
3e. INSTALLATION :
positions.
a) Loosen the lock nuts on each valve lever and
4) Remove the thermostat housing by pass
back off the adjusting screws.
hose (6-3)
b) Install the valve rocker arm shaft assembly
5) Remove the three bolts then remove the
on the studs as shown in Fig. 3 and install
thermostat housing (7-3).
the nuts (1-3) finger tight.
6) Remove the fuel injector pipes. It is not
c) Install the bolt in the centre bracket then
advisable to disconnect them at the injector
tighten the nuts to the correct torque.
only. They may become distorted.
d) Adjust the valve clearance as detailed in
7) Remove the cylinder head bolts
para 3f “ADJUSTMENTS”.
progressively in the reverse order to the
e) Install the valve housing cover using a new tightening sequence ref. Fig.4.
gasket and rubber washers.
8) Remove the cylinder head and gasket.
f) Install the nuts over the clamps/stiffner (over
NOTE : 1. Clean the Engine externally. Mark
valve housing). Then tighten them to the
dismantaled parts such as valves, Valve
specified torque.
stem guides and springs and place
them on a table in removal order to
faciliate reassembly.

NOTE : 2. Always cap all exposed openings of a. Inspect the casting for cracks and
injector pump, injector pipes, fuel lines burnt metal around the valve ports.
and nozzle holders to prevent entry of b. Check the valve seats for cracks
dirt into the fuel system. and pitting.
3. To avoid warpage do not remove c. Position a lamp underneath the
cylinder head bolts unless the engine valve guides and examine the bore
has cooled down. of the guide for burning, cracks or
23
signs of excessive wear.
4b. DISMANTLING d. Check the diameter of the guides
1) Remove the four nuts and conical washers at several points against the
securing the injector clamps. Carefully dimensions given in
withdraw the injector and copper washers SPECIFICATIONS.
from the cylinder head. Keep the injectors If the running clearance between
in a clean place free from dirt and dust. valve and valve guide exceeds
NOTE : Before disassembly of injectors, inspection 0.2 mm the valve guide should be
or repair of nozzles, contact Bosch dealer/ replaced.
service. e. Inspect the cylinder head and crank
2) Using a valve spring compressor, compress case for warpage if engine has
the valve spring sufficiently to allow removal been run with a blown head gasket.
of the collet (8-5). 4d. BEFORE REWORK
3) Release the pressure then remove the Check whether the cylinder height permits
retainer (7-5) and spring (3-5) the valve seat reworking.
should also be removed.
4) Remove the valve (2-5) and identify them so
that they can be installed in the original
positions.
5) If necessary press out the valve guides from
the under side of the head using pusher
slightly smaller than the guide to prevent it
jamming in the bore.
4c. CLEANING, INSPECTION & REPAIR

(a) CLEANING
1. Wash all parts in diesel.
2. Remove any old gasket material from
the faces of the cylinder head.
3. Blow through all oil passages to ensure
that they are clear.
4. Remove all carbon deposits from the
cylinder head and valves.
5. Remove any carbon deposits from the
valve guides, using a wire brush. Blow
out loose carbon with compressed air.
Fig. 5
NOTE : Guides require careful cleaning because any
remaining carbon will deflect the pilot of a 1. Intake valve 6. Valve spring retainer cup
valve seat refacing tool. 2. Exhaust valve 7. Valve spring retainer cup
(b) INSPECTION 3. Valve spring 8. Valve spring lock (collet)
4. Valve stem guide 9. Valve stem seal
1. The Cylinder Head.
5. Valve seat insert

1. Camshaft
2. Tappet
3. Push rod
1
4. Cylinder head
5. Adjusting screw locknut
6. Adjusting screw 2
7. Valve lever
8. Valve spring retainer
9. Valve spring - outer
24
10. Valve spring - inner
11. Valve spring seat
12. Valve guide
13. Valve
Fig. 8 - Cylinder Head
1. Injector Mounting Nut

Fig. 6 2. Injector
Fig. 7
1. Gear 9. Rocker 17. Bracket 25. Pin
2. Screw 10. Circlip 18. Nut 26. Lock
3. Washer 11. Washer 19. Washer 27. Cup
4. Plate 12. Screw 20. Shaft 28. Spring
5. Key 13. Nut 21. Plug 29. Washer
6. Camshaft 14. Arm, rocker 22. Spring 30. Set
7. Tappet 15. Arm, rocker 23. Spacer 31. Valve
8. Rod 16. Bush 24. Bracket 32. Valve

Check to see if nozzle tip protrusion will retain

within specified limits after rework.
(Nozzle protrusion of 2.3/1.8 mm is to be ensured)
To remove valves compress valve springs with valve
spring compressor tool and take out spring retainer
locks.
To remove valve seat inserts, first weld two opposite 25
Fig. 11
lugs fig. 11 to provide puller grip.
1. Exhaust valve seat insert 2. Welded lugs
Observe checking pattern, fig. 12 see “Specification”.

f) Check the valve stems for bends, wear, pitting
or mush-rooming of the ends. Check the collet
grooves in the stems to ensure they have not lost
their shoulders.
g) Check that the valve heads are not excessively
worn or pitted.
h) Check the valve springs for rust, pitting or cracks
and against the loads given in specification.
Fig. 9 - Removing valves
4e. CLEANING, INSPECTION AND REPAIR

Clean the cylinder head thoroughly.
Remove carbon deposits from the bottom of the
Fig. 12 - Checking pattern, cylinder head and crankcase
cylinder head and out of exhaust valve ports.
Fig. 10 - Removing valve seat inserts

Fig. 13
Flush out the water jacket to remove scale and
dirt. i) Check the retainers for rust and cracks.
NOTE : Make sure water passages are free of j) Check and replace valve seals.
obstructions, rust or scale.
k) Check the outside face and the ribs inside the
collects for wear. It is advisable to always use
Inspect the cylinder head (and the crankcase) for new collets.
warpage if engine has been run with a blown head l) If the new valve guides are replaced, ream the
gasket. Illust 13. valve guides to the dimensions given in
specifications.

m) If the valve seat inserts are to be replaced, take

DEPRESSION
a fine cut, if necessary, from the bottom of the
counter bore, to ensure a square seat for the MM
replacement insert. (See fig. 10)
Inlet 0.89/0.48
n) Thoroughly chill the new valve seat inserts at
Exhaust 1.20/0.78
-600C in dry ice before installation. This prevents
metal scraping from the side of the counterbore,
ensuring full contact of the insert on the bottom e) Install the injectors and tighten the nuts to the
26
and side of the counterbore. After installation specified torque.
inserts peen over the edge of the inserts around f) Check to see if nozzle protrusion will remain
it’s entire circumstance. The inserts should be specified limits after rework. (Nozzle protrusion
recessed in the Head 0.15mm to 0.35mm. of 2-3/8 mm is to be ensured)
When using carbon dioxide or dry ice, strictly
adhere to instructions to avoid injuries. Do 4g. INSTALLATION :
not touch deep frozen parts with bare hands. a) Apply a light coating of clean engine oil to the
cylinder head mating face and install new gasket.
o) Reface the valve seats to the correct angle seat
that are too wide after refacing should be b) Install the guide studs with special service tool
narrowed by grinding the top edge of the seat (fig.16) in the cylinder block to hold the gasket
with a stone of a similar angle (15 0 angle in place and ensure the correct alignment of the
preferred). Refer Fig. 15 cylinder head while installation.
p) Mount a dial indicator on the pilot shank and c) Install the cylinder head.
check that seat run out does not exceed Before installation the cylinder head check cylinder
0.08mm. sleeve protrusion. ref. fig. 11 chapter 3 If
q) Reface the valves but reject valves that grind protrusion is not within specification remove the
down to a fine edge. sleeve and follow the complete procedure.
r) Using carborundum paste lap-in the valves. d) Install the centre rocker arm lever shaft bracket
Ensure that all carborundum paste is removed on cylinder head and insert the long bolt.
from the valve and valve seats after lapping. e) Remove the guide studs then insert the remaining
Excess paste must be removed with a cloth and bolts.
the head washed in the solvent and blown dry f) Tighten the bolts progressively in the order shown
with compressed air. in Fig.4 to the specified torque by special service
s) Check the valves in their seats using engineers tool MST-H1/2-EN-6 (fig 13a)
blue. A complete ring of contact must be shown NOTE : Be sure there is no oil i.e. the bottom cylinder
on both faces. head bolt holes to prevent hydraulic lock
t) If the end of the valve stems are found to have when the bolts are torqued.
developed indentation (due to constant hitting of g) Remove the long bolt from the centre valve rocker
rocker arm) the same should be removed by fine arm shaft bracket and remove the bracket.
grinding the tips and removing sufficient metal
h) Install the push rods in their original position.
so as to give flat & smooth finish. However either
valves or the rocker arms which have deep i) Assemble the valve rocker arm assemblies as
indentations should not be salvaged. detailed in Para 3d. Loosen the lock nuts on each
valve lever and back of the adjusting screw.
j) Install the valve rocker arm assembly as detailed
4f. ASSEMBLY :
a) Coat the valve stems with clean engine oil and
install them in their original position.
b) Install the valve spring seat and valve seals.
c) Install valve springs and retainer. Using valve
spring compressor, compress the spring and fit
the new collets.
d) After assembling the valves, ensure that the valve
depression below the cylinder head mating face
is as per the following specifications : Fig. 13a

in 3e.
Replace the longer cap screw through the center
bracket and retorque to the correct figure.
k) Install the thermostat housing.
l) Install the thermostat bypass hose.
m) Reassemble the fuel injection pipes.
n) Fit the spill pipe to the injectors and fuel return 27
pipe.
o) Refit the intake and exhaust manifolds as
detailed in Para 2b.
p) Adjust the tappet clearance after the cylinder
head tightened to the correct torque for
adjustments see para 3f.
Tips for service of cylinder head

1) During cylinder head overhaul, Nozzle protrusion
Fig. 14 (protrusion of nozzle tip from head bottom face)
should be checked thoroughly as it affects the
fuel spray pattern of the nozzle.
2) Excessive carbon deposition on valve neck and
valve stem indicates engine oil consumption due
to excessive clearance between stem and valve
guide.
3) Discard valve springs if they have lost tension
or are broken.
4) Always replace valve collets whenever valves are
opened for inspection or repairs.
5) Improper valve spring tension, valve lapping,
tappet setting, timing or excessive cam lobe wear
will cause valve seat damage and subsequent
leakage.
6) While replacing piston rings ensure that the valve
seats are ground/lapped for perfect seating to
avoid oil throw from the exhaust.
Fig. 15
7) While regrinding the valve maintain it’s
Replacing the valve seat concentricity with the guide to ensure proper
seating.
8) Never remove the cylinder head in hot condition.
Fig. 16
The Guide Stud

Engine - Connecting Rods, Pistons & Cylinder Sleeves
28
Chapter-3 Connecting Rods, Pistons & Cylinder Sleeves

Description
Connecting Rod & Piston Assembly Removal
Cylinder Sleeve Removal
Cylinder Sleeve Inspection & Repairs
Running in Schedule

1. DESCRIPTION 2. CONNECTING ROD AND PISTON ASSEMBLY

Connecting Rod are forged steel. The big end is a) REMOVAL :
mounted on the crankshaft and the small end is
1) Remove the cylinder head as detailed in
connected to the piston by piston pin. chapter 2. Para 4a.
2) Remove the carbon ridge at the top of each
sleeve.
3) Remove the bolts securing the oil pan to 29
the crankcase and pull out the oil pan.
Remove the gasket from the crankcase and
discard it.
4) Remove the bolt securing the oil pump to the
crankcase and carefully withdraw the oil
pump. Take care not to damage the teeth in
the pinion gear.
5) Take off connecting rod bearing caps (2-1)
with bearings and lift out pistons with
connecting rods, by pushing up and out of
the sleeve.
6) Replace bearing caps (8-2) with inserts (9-
2) on connecting rods to prevent mixing up.
7) With long-nose pliers remove piston pin
retainer springs by squeezing pronged ends,
fig. 4.
NOTE : If the cylinder sleeve has been worn so that
Fig. 1 there is a ridge in the sleeve at the upper
end of the piston travel, this must be
removed before the piston is withdrawn, to
prevent damage to the ring lands and rings
during removal of piston.
7
10
8
9
1. Sleeve 7. Connecting Rod 12. Compression

2. ‘O’ Ring 8. Conn. Rod Cap Ring Fig. 3 - Connecting Rod & Piston Assembly
3. ‘O’ Ring 9. Conn. Rod Bearing 13. Oil Ring 1. Cylinder Number 5. Travelling direction
4. Piston 10. Conn. Rod 2. Ignition bowl 6. Top compression ring
5. Pin Small End Bush 3. Left side of connecting rod 7. Zud Compression ring
6. Circlip 11. Compression Ring 4. Camshaft side of 8. Oil control rings
Fig. 2 connecting rod 9. Piston pin snap ring

30
Removing or installing piston rings with ring expander
Fig. 5
line (A-4), if necessary realign by straightening

the connecting rod or replace them.
d) Check the threads in the connecting rod big end
for wear and damage.
Fig. 4 - Removing or installing piston pin circlips
3. INSPECTION AND REPAIRS :

NOTE :
i) Do not hold the piston in a vice.
ii) Always service/change the piston and piston
pin as a set.
Connecting Rod Alignment
iii) It is advisable that, whenever the piston and
the connecting rod assembly is removed
from the sleeve new piston rings be installed
while re-assembling.
a) Check the piston ring grooves for wear, using
new ring and feeler gauges (Fig. 5). See
specifications for acceptable clearance.
b) Check the pistons for seizure or/and overheating
marks.
c) Check the connecting rods for alignment (Fig.6).
The bores must be square and parallel with each
other in all planes within +3mm (+0.13mm)
(L-4) measured 127 mm each side of the centre Fig. 6 - Checking connecting rods for squarenss

NOTE : Do not rotate the crankshaft while this check

is being made.
1) Assemble the insert to the connecting rods
and caps.
2) Lay a length of plastigauge across the
bearing cap insert.
3) Install the connecting rod on the crankshaft 31
all the main rod and tighten bolts to the
correct torque.
4) Remove each bearing cap and measure
thickness of the plastigauge to determine the
bearing clearance.
Remove the connecting rod from the
crankshaft.
4. ASSEMBLY :
a) Push the piston pin into boss of the piston.
b) Position the connecting rod inside the piston
and align the bushing with the piston pin.
Fig. 7 During the assembly of the piston and the
connecting rod, ensure that the combustion
e) Check the wear and condition of the connecting cavity in the piston is towards the F.I. Pump
rod bushings. If replacement is necessary side.
proceed as follows : c) Before installing sleeve, check that the
1. Press out the old bushing (10-2) counterbore at the top and sealing ring
2. Align the oil hole in the new bushing with the groove at the bottom are clean and free
oil hole in the connecting rod and, using a from foreign material. All sleeves should
pilot dolly, press the bushing into the rod. enter crankcase bores full depth and should
3. Ream the bushing to the dimension given in free to rotate by hand. (without sealing ring)
specifications and check the fit of the piston NOTE : The cylinder head gasket forms the upper
pin. cylinder sleeve seal, and excessive sleeve
f) Check the piston pin for wear or corrosion. standout will result in coolant leakage. To
test lower sealing rings for proper
g) If the piston pin is a slack fit in an otherwise
installation, fill crankcase water jacket with
serviceable piston, the piston bore and
cold water and check for leaks near bottom
connecting rod bushing can be reamed to take
of sleeves.
an oversize piston pin. Refer the specifications
for dimensions. d) Push the piston pin into the other boss and
install the circlips on both sides of the piston
h) Insert piston ring in bore and use a piston
securely. The piston pin can be pushed with
without ring to it square in the bore. Check the
slight hand pressure.
ring gap (Fig. 7).
e) Using piston ring expander fit the rings to
i) Repeat operation (h) with each piston ring and
the piston starting the bottom ring and
reject anywhere the gap exceeds. (0.76mm).
working up.
j) Check new rings in the same manner, as
NOTE : Multi-piece oil control rings should be fitted
detailed in operation (h) and check the gap to
to the top oil control groove. The expander
specifications. The ends of the ring may be filled
(1-8) must be installed first, followed by the
carefully to bring the gap within the limits.
two flat rings (2-8) either side of the expander.
k) Check the clearance between the connecting rod The gaps in the flat rings must be at 1800
bearings and the crankshaft as follows :- to each other.

Piston Rings
b) Check piston ring gap using a feeler gauge.
NOTE : To check piston ring gap the ring must be
placed squarely in a new cylinder sleeve
(Fig. 7). Replace piston ring as a set only.
32 Piston Clearance to Cylinder Sleeve

Check the piston clearance in the sleeves using a
0.10 mm ribbon gauge 12 mm wide with a tension
scale in the following manner;
a) Position the ribbon in the cylinder bore so that
it extends the entire length of the piston, 90
degrees from the piston pin location.
b) Invert the piston and install it in the bore so that
the end of the piston is about 38 mm below the Fig. 8
top of the cylinder block and the piston pin is

parallel to the crankshaft axis. NOTE : When correctly positioned, the connecting rod
cap bearing half will stand out 0.7 mm above
c) Hold the piston and slowly pull the scale in a
the cap surface and will engage inside the
straight line with the ribbon, noting the pull
connecting rod half bore. Failure to position
required to remove the feeler ribbon. Do not
correctly will result in the bearing halves
bend or kink the ribbon gauge.
being out of line when the bearing cap bolts
d) Measure and check the clearance with the piston are torqued.
pin at right angles to the crankshaft axis. (Refer
g) Install the oil pump as detailed in chapter 4
to “Specifications”)
para 7.
It should require 0.9 to 2.7 kgs. pull to move the
h) Install the cylinder head as detailed in chapter
ribbon gauge.
2 para 4g.
5. INSTALLATION : 6. DISMANTLING :
a) Immerse the piston assembly in clean engine Using a piston ring expander, remove the piston
oil and fit a ring compressor over the piston. rings in the following order. First, remove the top
b) Place the connecting rod in the correct compression ring (Fig 11-2); then remove the
cylinder and push down steadily on the second compression ring (Fig 12-2) and finally
piston until it is completely in the cylinder. remove the third conformable oil control ring
c) Wipe the crankshaft bearing end of the rod (Fig. 13-2) and the expander. Remove the two
to remove and dirt gathered during circlips (Fig 6-2) and push out the piston pin
installation. Wipe the bearing upper half (Fig 5-2) out of the pin boss. The pin can be
clean then fit it to the connecting rod. Apply pushed out by applying a slight hand pressure.
oil to the bearing surface and position the Identify the piston pin and the piston (Fig 1-3)
connecting rod on the crankshaft with the with a paint mark or a tag. Do not interchange
number to the F.I. pump side. pins and pistons while assembling.
d) Wipe the bearing cap and lower half bearing The connecting rod can be removed and
clean then assemble together. Apply oil to installed without having to separate the engine
the bearing surface and install the cap on from the clutch.
the connecting rod with the number to the The weight of con-rod at the crankshaft and
F.I. pump side. piston is balanced and no material should
e) Tighten the bolts to the specified torque. therefore be removed or added as this would
f) Proceed as detailed in ops. (a) to (e) for the disturbed the balance.
remaining piston assemblies. Connecting rods are classified by different weight
groups of which only the medium group is
available for service.

Care should be taken when replacing connecting

rods, that all connecting rods of the engine are
of same weight group, to keep the crank shaft
assembly well balanced.
Replacement of a piston pin bushing is an
exacting service job which call for precision
equipment and skilled and experienced
serviceman. 33
Piston pin bushings are furnished semi finished
and must reamed after installation to provide
0.01mm - 0.02mm clearance for the piston pin.
Be sure oil holes in bushing and control align
after the bushing is installed.
Connecting rod bearing are available in standard
Fig. 10
size as well as under size 0.25, 0.38, .05 &
0.76mm
NOTE : Weights refer to complete connecting rods
with bushing, bearing cap and bolts but less
securing wire and without bearing halves.
Fig. 11
2. INSPECTION AND REPAIR (See fig.10)

Fig. 9 Agreement of piston rings (Piston with insert 4)
a) With the sleeves in the crankcase measure
1. 1st compression ring 4. Insert the bores at the top (A) and the bottom
2. 2nd compression ring A. Piston pin bore nominal
(B&C) at 900 to the crankshaft to determine
3. Oil control ring
the amount of taper.
b) Compare the readings from op. (a) with
7. CYLINDER SLEEVES
those from op. (b) to determine the amount
1. REMOVAL of ovality as per specification.
Check cylinder sleeve wear before removal The cylinder sleeves should be renewed
see fig. 10. when out of round exceeds 0.20mm and
NOTE : Removal on the cylinder sleeves need only taper exceeds 0.13mm. The old cylinder
be carried out if inspection proves this sleeve should be removed with the help of
necessary. special service tool MST-H1-EN-1 (fig.13) as
a) Remove the piston assemblies as detailed follows :
in para 2a. Insert the sleeve puller from the top of
b) Using a suitable sleeve puller withdraw the the crankcase (fig.14).
cylinder sleeves. Fix the thrust plate sides at lower portion
c) Remove the sealing ring from the groove in of cylinder sleeve. The bigger side of
the crankcase bore. And discard it. thrust plate is suitable for DI Engine.

Position the bracket on top of the NOTE : Weights refer to complete connecting rods
crankcase and tighten the nut over the with bushing, bearing cap and bolts but less
bracket of puller bar, by rotating handle, securing wire and without bearing halves.
the sleeve will be pulled out while c) Check from below to ensure that the packing
tightening the nut. rings have not been sheared or pushed out
c) Before installing sleeve, check the counter of position.
bore at top and sealing ring groove at the d) Check the cylinder sleeve protrusion (Fig.11)
34 bottom are clean and free from foreign to specifications. The top face of the sleeve
material. All sleeves should enter crankcase can be 0.05 mm above the cylinder block
bores full depth and should free to rotate by face or 0.03 mm below the cylinder block
hand (without sealing ring). face. To ensure the above dimension, the
NOTE : The cylinder head gasket forms the upper cylinder sleeve and the cylinder block should
cylinder sleeve seal, and excessive sleeve be matched.
stand out will result in coolant leakage. To NOTE : Check cylinder sleeve protrusion according
test lower sealing rings for proper to checking sleeve protrusion procedure
installation, fill crank case water jacket with given below :
cold water and check for leaks near bottom
e) Install the piston assemblies as detailed in
of sleeves.
para 5.
d) Check the sleeves for scoring or signs of
1. Place the sleeve in the crankcase with out ‘O’
corrosion.
Ring.
2. Clamp the sleeve down using four holding
adapters/plate shown in fig 12 place sleeve
holding plate locally.
Space the bolts to obtain uniform pressure on
the sleeve flange as shown in figure. Torque the
bolts equally in three stage as specified torque
3. Place a dial indicator with block, across the
cylinder sleeve.
3 4. With dial indicator pointer set on the flange of
1 2 the cylinder sleeve. Adjust the indicator to zero.
Fig. 12 Move the indicator block until the pointer drops
1. Sleeve 2. Holding plate 3. Bolt
to the crankcase deck and check the reading.
5. Take a reading three or four points around the
sleeve and use the average reading normally the
top of sleeve will extend 0.076mm - 0.18mm
above the cylinder block surface.
6. Mark each sleeve before removing so that it can
be reinstalled in the same bore and in the same
position.
Fig. 13 Fig. 14
3. INSTALLATION
a) Dip each cylinder sleeve packing ring in a
soap solution and install it in the groove in
the crankcase bore.
b) Coat bottom of each sleeve with soap
solution and press the sleeve into the
crankcase bore.

4. CONDITIONING SCHEDULE c. OPERATION

a. GENERAL 1. RUNNING IN SCHEDULE
After installation of new sleeves, pistons or piston Following running-in schedule is recommended:
rings, the engine must be run in before being HOURS :
operated at full load and speed. The first phase
First 25 hrs.
of running in must be gentle enough to prevent
excessive pressures and temperatures but, if too Load : Apply 25% of normal Load
Haulage : 2 - 4 tonnes on level road in low gears. 35
gentle may result in cylinder wall glazing due to
low combustion temperatures and incomplete e.g. H2 / H3
combustion which results in short engine life, loss Primary Tillage : Depth 101mm - 127, in L1 gear
of power and high oil consumption. Secondary Tillage : Depth 76mm - 101mm in
Until the engine is run in the following conditions L3 gear
may be noted :-
1. Low compression, poor combustion and 25 - 50 hrs.
smoking. Load : Apply 50% of normal Load
2. High oil consumption. Haulage : 4 - 6 tonnes on mild slope in H2 / H3
3. Blow by will be high. gears
Primary Tillage : Depth 127mm - 152mm in
L1 / L2 gear
b. PREPARATION
Secondary Tillage : Depth 101mm - 127mm
a. Check and fill the cooling system
in L3 / H1 gear
b) Check the level of oil in the crankcase.
c) Bleed the fuel system as detailed in the
relevant Operator’s Manual.
d) Start the engine and run at 1/4 throttle
operating until operating temperature is
reached.

Engine - Lubrication Systems
36
Chapter-4 Lubrication System

Description
Oil Pump Removal
Inspection & Repair
Assembly
Oil Cooler

A. GENERAL
Mahindra Tractors have 2, 3 or 4 cylinder direct injection water cooled diesel engines with inline fuel injection
pumps and overhead valves. These engines have superior specific fuel consumption with very low smoke
emission and very low crankcase oil dilution.
37
LUBRICATION CIRCUIT DIAGRAM

A. DESCRIPTION a) Remove the two bolts (2-3) which secure the

Lubricating pump is a four lobe internal gear oil pump screen (1-3) to the pump body
pump. The pump is driven by a gear on the cover (3-3) and remove the screen.
camshaft. The pump has a built-in relief valve to b) Drive out roll pin (3-4) then remove the
limit maximum pressure. coupling (2-4) and pinion (4-4) from the
shaft.
B. OIL PUMP c) Remove bolts (4-3) which secure the cover
38
to the body.
d) Remove cover (12-4).
(e) Remove the shaft assy. (7-4) from the pump
body (5-4).
(f) Remove Retainer plug (19-4) then lift out
regulating spring (17-4) and relief valve
(16-4) and gasket (18-4).
Fig. 1
Fig. 3
1. REMOVAL
a) Remove the crankcase drain plug and drain 3. INSPECTION & REPAIR
the oil while the engine is warm.
Check the oil pressure regulating valve spring.
b) Install the drain plug then remove the bolts Check the oil pressure regulating valve and seat
securing the oil pan to the crankcase and, for wear, pitting, or corrosion. Check the drive
remove the oil pan and gasket. shaft to pump body clearance. Check the drive
c) Remove the bolt (1-1) securing the oil pump spin-on for wear or damage. Check the
(2-1) to the crankcase and withdraw the oil clearance between the lobes of the rotor (refer
pump. fig.2). It should not be more than 0.25 mm.
2. LOBE TYPE
Fig. 2
Checking clearance between rotors Fig. 5

39
1. Pump cpte. 7. Rotor shaft assembly 13. Bolt long 19. Retainer
2. Coupling Hourmeter drive 8. Shaft 14. Bolt short 20. Screen
3. Roll pin 9. Rotor inner pump 15. Washer 21. Bolt
4. Pinion 10. Lock pin 16. Plunger valve 22. Spring washer
5. Body oil pump 11. Rotor 17. Spring
6. Key 12. Cover oil pump 18. Gasket
Fig. 4

Check the clearance on the end of the rotors. 5. ASSEMBLY GEAR TYPE PUMP
Check the clearance between outer rotor and a) EARLY ENGINES
rotor pocket (refer fig. 2). The clearance should
Insert a key into the drive shaft then press
not be more than 0.3 mm. Always service/
on the body gear until the retainer groove
replace the inner and outer rotors as an
is exposed. Spring the gear retainer into the
assembly.
groove and press the gear back down the
shaft until it is hard against the retainer then
40
4. INSPECTION AND REPAIR install the drive shaft and gear in the oil
a) Check the oil pressure regulating valve pump body.
spring (17-4) against the loads given in CURRENT ENGINES
specifications. Install the drive shaft and gear in the oil
b) Check the oil pressure regulating valve pump body.
(16-4) and seat for wear pitting or corrosion. b) Fit the key into the shaft and press on the
c) Check the drive shaft to pump body drive spin-on, aligning the hole in the gear
clearance to specifications. with that in the shaft.
d) Check the drive pinion (4-4) for wear or c) Drive in a new roll pin.
damage. d) Install the coupling and drive in a new roll
e) Check the gears for wear, damage or pitting. pin.
Burrs can be removed from the gears using e) Using a new gasket assemble the gear case
a fine carborundum stone. The oil pump to the oil pump body.
plate can if necessary be ground flat using
f) Install the regulating valve and spring in the
surface and carborundum paste.
oil pump body.
f) Check the backlash between the gears to
specifications. g) Install the idler gear.
g) Check the clearance between the gears and h) Using a new gasket install the pump end
end plate as follows : cover and tighten the bolts to the correct
torque.
1. Install the gear case on the pump body
using a new gasket. i) FIXED SCREEN
2. Install the gears, then place a length of Assemble the screen to the pump end cover
plastigauge across the top of each gear. and tighten the bolts to the correct torque.
3. Install the end cover using a new gasket

and tighten the bolts to the specified 6. ASSEMBLY : LOBE TYPE PUMP
torque. Install the rotor shaft assembly in the oil pump
4. Remove the cover and measure the body. Fit the key in to the shaft and press in the
thickness of the plastigauge. This must drive gear with that in the shaft. Drive in a new
not exceed the dimension given in roll pin. Install the outer rotor. Install the pump
specifications. end over and tighten the bolts to the correct
h) All sealing rings and gaskets must torque. Assemble the screen to the pump and
discarded. If the clearance is excessive tighten the bolts to the correct torque. Assemble
check the end plate using a straight edge the relief valve inside the pump body and install
and feeler gauges. If necessary, the end the spring. Tighten the retaining bolt using a new
plate can be ground flat using a sheet of washer.
crocus paper on a surface plate. Assemble
the end plate and re-check the clearance. 7. INSTALLATION
i) If no clearance exists, insert one additional a) Install the oil pump in the crankcase then
gasket and re-check the clearance. tighten the bolt to the correct torque.
j) Check the clearance between the oil pump b) Use a new gasket and install the crankcase
drive pinion and the body after the pump is oil pan, tightening the bolts to the correct
assembled (Fig 5). torque.

c) Fill the crankcase with the correct grade of 8. OIL COOLER

lubricating oil to the oil level mark on the Description :
dipstick.
a) It is used to cool Engine Oil.
b) Hot Oil enters through intake of Oil Cooler,
C. LUBRICATING OIL FILTERS Circulates in tubes around which water
continously flows. This Flowing water takes
the heat from the oil and makes it cool. 41
1
5
4
6
1. Adaptor Oil Cooler

2. Oil Cooler (5 Plate)
3. Hose Oil Cooler Inlet and Outlet
4. Clip Pipe Res. To Pump-Worm TYP
5. Pipe Oil Cooler Outlet
6. Pipe Oil Cooler Inlet
7. Bracket Oil Cooler Pipe
1. Washer
2. Filter
3. Adapter
4. Gasket
5. Bolt
Fig. 6
1. REMOVAL
a) Remove the two bolts (5-6) securing the filter
to the crankcase (3-6) then remove the filter
and gasket (4-6).
b) Unscrew the spin-on oil filter (2-6) from filter
head and install new filter.
NOTE : Engine Oil and filter element must be
changed after every 250 hours of engine
operation.

Engine - Timing Gear Train, Front Cover & Camshaft
42
Chapter-5 Timing Gear Train, Front Cover & Camshaft

Description
Front Cover Removal & Assembly
Timing Gears Removal
Timing Gears Inspection, Repairs & Installation
Camshaft Removal
Camshaft Inspection, Repairs & Installation

A. DESCRIPTION d) Pull the fan driver pulley off the crankshaft

1. GEAR TRAIN and remove the key.
The timing gear train consists of four gears. The e) Remove the nuts and bolts securing the
Crankshaft pinion, the camshaft gear, the idler injection pump gear cover (4-1) then remove
gear and the injection pump gear. These gears the cover.
are mounted on the front plate face of the engine f) Remove the two bolts (1-1) from the front
and are covered with the cast iron crankcase of the crankcase oil pan.
front cover. Each gear is punch marked for timing 43
g) Remove the bolts (5-1) securing the front
purpose. cover then remove the cover and gasket.
NOTE : Check the backlash between the gears to
2. CAMSHAFT
specifications if necessary.
The special cast iron/forged camshaft runs in
babbit lined bushes in the right hand side of the 2. DISMANTLING
crankcase. The camshaft bushes are replaceable
Press out the oil seal if inspection proves it
and are supplied for service in a semi-finished
necessary.
bored condition and must be line reamed to size
after filling. A gear integral with the camshaft 3. ASSEMBLY
provides the drive for the oil pump.
Press in a new oil seal with the lip facing inward
The camshaft is driven from the front end of the until it is flush with the outside face of the front
crankshaft through a train of gears. All gears are
cover.
punch marked to ensure correct tuning. End float
is controlled by thrust washer plate (4-3). The 4. INSTALLATION
drive gear is key shrunk to the camshaft end.
Reverse the removal procedure.
B. FRONT COVER C. TIMING GEARS

1. Removal 1. REMOVAL
a) Remove the fan belt and fan as detailed in a) Timing Gear Cover
cooling system Group 4. To remove the timing gear cover, first
b) Remove the starting crank nut (2-1) and remove the front support, axle and radiator
lockwasher with the help of Special Service assembly as follows : Drain cooling system,
Tool. raise hood and disconnect headlight and
c) Remove hydraulic pump mounting bolts pull horn wires at junction on front support, then
hydraulic pump out somewhat and move unclip loom from radiator. Remove hood
slightly towards the outside. pivot bolts and remove hood. Do not lose
the pivot bolt spacers. Disconnect radiator
brace. Disconnect upper and lower hoses
from radiator. Disconnect the drag link. If
tractor is equipped with hydrostatic steering,
disconnect the steering cylinder hoses, then
cap and plug all openings to prevent dirt
from entering system.
Then, on all tractors, place wood blocks
between steering gear housing and axle to
prevent tipping. Using a suitable jack,
support tractor under clutch housing. Unbolt
stay rod bracket from clutch housing and
steering gear housing from front of engine
if mechanical steering is fitted. Raise engine
until crankshaft pulley will clear front axle
support. Then roll out from axle support with
Fig. 1 front axle and tyres.

3. INSTALLATION
a) Fit a new key to the crankshaft then press
the crankshaft pinion on to the crankshaft.
b) Assembly the idler gear and shaft, install it
on the crankcase ensuring that the double
marks on the idler gear line up with the
double marks on the crankshaft spin-on.
44
Tighten the bolt to the specified torque.
c) Install the camshaft and camshaft gear as
detailed in para D-4.
d) Install the injection pump gear ensuring that
the double marking on the injection pump
gear is in register with the single marking on
the idler gear, install the three bolts and
tighten to the correct torque.
e) Install the front cover as detailed in
para 3-4.
D. CAMSHAFT
1. REMOVAL
NOTE 1 : Before camshaft removal check
a. Backlash of camshaft drive gear
b. Camshaft end float
Fig. 2
c. Cam lobe lift
b) Remove the front cover as detailed in para NOTE 2 : Cam lobe lift may be checked by means
B-1. of a dial indicator gauge.
c) Remove the three bolts (1-2) then remove Rest the stylus of the dial indicator on one of the push
the injection pump gear (2-2). rods.
d) Remove the idler gear shaft bolt (3-2) then Rotate the engine one revolution and note dial
remove the idler gear and shaft (4-2). indicator reading. Compare reading with “specifications”.
e) Using a suitable puller remove the a) Remove the valve rocker arm shaft assembly
crankshaft pinion (5-2) and key. as detailed in CHAPTER 2 para 3a.
f) Remove the camshaft gear (6-2) as detailed b) Lift out the valve push rods and identify them
in para D-2. so they can be installed in their original
positions.
2. INSPECTION AND REPAIR c) Remove the crankcase front cover as
detailed in para B-1.
a) Inspect the gears for wear and cracked or
chipped teeth. Remove any burrs on the
gears with a fine carborundum stone.
b) Inspect the fan drive pulley for wear or
cracking.
c) Check the fit of the idler gear and shaft to 1. Gear
specifications. 2. Screw
3. Washer
d) Check the condition of the idler gear shaft
4. Plate
bolt thread insert in the front of the 5. Key
crankcase. If inspection proves if necessary 6. Camshaft
remove the thread insert and fit a new one
Fig. 3
as detailed in chapter 6 para D-2 installation.

d) Remove the oil pump as detailed in b) Fit a new key to the camshaft then press on
CHAPTER 4. the camshaft gear to leave a clearance of
e) Invert the engine then turn the camshaft until 0.20-0.43mm between the gear hub rear face
the cored holes in the gear line up with the and the thrust plate. Ensure that the thrust
bolts (7-2) (2-3) securing the camshaft thrust plate is located against its abutment shoulder
plate then remove the bolts and lockwashers. when checking this clearance (fig.5)
f) Withdraw the camshaft with gear from the
crankcase. 5. INSTALLATION 45
g) Remove the valve tappets (1-4) and identify a) Install the valve tappets in their original
them so they can be installed in their original positions.
positions. b) Coat the camshaft and camshaft bearings
with clean engine oil.
2. DISMANTLING
c) Install the camshaft in the crankcase taking
a) Press the camshaft out of the gear then
care not to damage the bearings and engage
remove the key and thrust plate from the
the camshaft gear with the crankshaft spin-
camshaft.
on ensuring that the single timing marks are
in register.
3. INSPECTION AND REPAIR
d) Secure the thrust plate to the crankcase with
a) Inspect the cam lobes and camshaft journals
the bolts and lockwashers and tighten the
for wear to specifications.
bolts to the specified torque.
b) Inspect the oil pump drive gear, if excessive
e) Invert the engine and install the oil pump as
wear is found, the camshaft must be replaced.
detailed in chapter 4 para 7.
c) Place the camshaft between centres and with
f) Install the front cover as detailed in para 3
a dial indicator against the centre journal
and 4.
check that the run-out does not exceed
0.05mm. g) Install the valve push rods in their original
positions.
d) Check the camshaft gear and thrust plate for
wear which will produce excessive end h) Install the valve rocker arm shaft assembly
clearance. as detailed in chapter 2 C-5.
e) Check the camshaft running clearance E. CAMSHAFT BEARING
against the dimensions given in 1. REMOVAL
specifications. If inspection proves it a) Remove the camshaft as details in para 4a.
necessary, remove the camshaft bearing as
b) Remove the flywheel as detailed in CHAPTER
detailed in para. E-1.
6, para B.
f) Inspect the valve tappets for wear to
c) use a long bar from the front of the crankcase
specifications.
and drive out the expansion plug.
4. ASSEMBLY
a) Install the thrust plate on the camshaft.
1. Camshaft
2. Thrust plate
3. Key
4. Gear
Fig. 4 Fig. 5

d) Remove the camshaft bearings bolts (1-2) and lock washers and tighten to
(2, 3 & 4 - 4) from the crankcase. the same specified torque.
2. INSTALLATION
a) Press the centre bearing into position aligning
the hole in the bearing with the hole in the
crankcase.
46
b) Press the front and rear bearings into position
ensuring that the edge marked “FRONT” is
to the front of the crankcase and that the
holes in the bearings line up with those in the
crankcase.
c) Line bore the bearings to the dimensions in
specifications.
d) After reaming, blow out the crankcase and
oilways to remove all foreign material.
NOTE 1 : Ensure that the rear bearings is pressed
in flush with the front of the bore in the
crankcase.
NOTE 2 : Bearings supplied for service are
supplied semi-finished and must be line
reamed to specified dimension after
assembly.
a) After reaming thoroughly blowout the
casting and oilways to ensure that there
is no metal deposit left.
b) Examine the tappet for signs of wear.
c) Do not attempt to straighten or repair the
camshaft. If any parts are suspect they
must be replaced.
NOTE 3 : When the engine is in the upright
position the tappet must be inserted one
at a time as the camshaft is installed
into the engine because the tappets are
held in position by the camshaft.
Possible the engine should be
supported in an inverted position.
a) Place tappet in position.
e) Install the rear bearing expansion plug
expansion plug using a good quality sealer
on the plug and seat.
f) Install the flywheel as detailed in CHAPTER
6, para B-C.
g) Install the camshaft as detailed in para 5 in
the crankcase taking care not to damage the
bearings. Engage the camshaft gear with the
crankshaft spin-on to ensure that single
timing marks are in line with each other.
Secure the thrust plate to the crankcase with

Engine - Crankcase, Cankshaft, Main Bearings & Flywheel
47
Chapter-6 Crankcase, Cankshaft, Main Bearings & Flywheel

Description
Flywheel Removal, Inspection, Repair & Installation
Crankshaft Removal, Inspection, Repair & Installation
Cylinder Block Inspection, Repair & Installation

A. DESCRIPTION : c) Remove the six bolts (2-3).

The crankshaft is supported in five main bearings d) Using a suitable sling to support it lever the
with end thrust being taken on the rear one, for flywheel off the dowels.
4 cylinder engine, 4 main bearings for 3 cylinder 2. Inspection and Repair
engine and 3 main bearings for 2 cylinder engine
a) Inspect the flywheel ring gear for excessive
with end thrust on the rear. The bearings are of
wear, chipped and broken teeth.
the steel backed insert type and do not require
48 fitting on assembly. The bearing caps, which hold b) If inspection proves it necessary replace the
the lower bearing inserts in position, are not flywheel ring gear as follows :
interchangeable and each one is stamped with CAUTION :
its location in the crankcase. No.1 is at the front.
1. Be sure the flywheel is exactly centered
The caps are secured to the crankcase by
when rotating it. The friction surface must
capscrews and lockwires in early models and by
be parallel with the dial face, deviation of
“Place” bolts, which do not require any locking
more than 0.05 mm are not permissible.
mechanisms, in later models.
Accidents occur occasionally to bearing caps and CAUTION :
in many cases it is undesirable to replace a 2. If ring gear has worked loose on the
complete crankcase when only a bearing cap flywheel, do not attempt by welding remove
requires replacement. A main bearing cap semi- the loose gear and replace with a new one
finished is available for such cases. However, it or replace flywheel with ring gear.
is necessary to have facilities to line bore for the
1. Remove the ring gear by heating with a torch or
finishing operation. The cap should be line bored
splitting with a chisel and driving off.
and finally line reamed. Specific dimension as
per specification chart. 2. Heat a new ring gear to 400-5500F and install
it ensuring that it is hard against the shoulder
The crankshaft supports the connecting rods and
on the flywheel. The ring gear must be installed
pistons along its length and converts the
with the lead on the teeth towards the crankcase
reciprocating movement of the pistons into the
on diesel engines (1-1). Permissible out of true
rotary movement required to drive the
of ring gear = 0.3 mm.
transmission. At the front end of the crankshaft
is the gear which drives the timing gear train and c) Inspect the clutch friction surface for ridges,
the pulley which drives the fan and water pump. scores, grooves, cracks and burn spots.
The flywheel is mounted on the rear of the
crankshaft and to this is mounted the clutch
which forms the link between the engine and
transmission. 2
CAUTION :
Extreme care must be taken to assure perfect 1
cleanliness of the crankcase, crankshaft and
bearings after service has been completed.
Whenever possible, the crankshaft should be
removed when new bearings are being installed
in order to clean the crankcase thoroughly. All
bearing surface must be free of grit and burrs.
B. FLYWHEEL 2
1. Removal
a) Removal of the flywheel required removal of
the Engine as in chapter 1 para 1a.
b) Remove the clutch assy as detailed in
Group 5 clutch. Fig. 3

d) Using a straight edge and feeler gauges exceed 0.025mm per 38.1mm of radius.
check the friction face for hollows or high If run-out exceeds this figure remove the
spots. The friction face must be flat and true flywheel and check the mounting faces on the
within 0.15mm. If necessary, the friction face flywheel and check the mounting faces on the
should be ground to this condition. If suitable flywheel and crankshaft for burrs or foreign
grinding equipment is not available the matter.
flywheel can be mounted in a lathe and the d) If run-out is within the figure in op. (c) bend
friction face dressed with emery cloth. If the up the tabs to secure the bolts. On current 49
surface is very rough take a fine cut with a engine the locktabs are deleted.
lather tool before dressing the friction face
with emery cloth.
Fig. 1
3. INSTALLATION
a) Install the flywheel on the crankshaft lining
up the dowel holes.
b) Install the bolts and tab washers then tighten
the bolts to the specified torque.
c) Mount a dial indicator on the crankcase and
check that friction face run-out does not Fig. 2

C. CRANKSHAFT BEARINGS AND CRANKSHAFT c) Check in the crankcase for sludge deposits.
1. REMOVAL These should be removed and the
crankcase thoroughly cleaned.
a) Crankshaft removal required removal of
engine from tractor as out line in chapter 5
para B-1-a. 3. THE BEARINGS AND CRANKCASE
b) Remove the clutch, flywheel as per chapter 1. Inspect the bearings for wear and evidence
50 6 para B. of uneven bearing support. If such evidence
c) Remove the timing cover as per chapter 5, is present, examine the bearing caps and
para 6-h. supporting surfaces of the crankcase for
d) Invert the engine. high spots and burrs.
e) Remove the rear oil seal retainer by 2. Inspect the crankcase for trueness, using the
removing 7 cap screws (fig 2-1). crankshaft as follows :
a) Wipe the bearing supports of the crankcase
free of oil with a lint free cloth. The
crankcase should be bottom side up and
levelly supported.
b) Install the upper halves of the bearings to
the crankcase. If the original bearings are
being reinstalled, ensure that they are fitted
to the positions from which they were
removed. The location nibs of the bearings
must fit into the notches in the main
bearings supports.
c) Smear blueing on the crankshaft main
journals and lower it carefully and evenly on
to the bearings. Do not install the bearing
caps and lower bearings.
d) Rotate the crankshaft back and forth through
approximately 1800, remove the crankshaft
evenly and inspect the upper bearing for an
even transfer of blueing from the journals to
the bearings.
1) Any bearings that do not show all over
even blueing should be replaced by
Fig. 4
new. It is advisable to replace all
bearings by new ones if an original one
f) Remove the bearing cap bolts (1-4). is faulty.
The remove the bearing caps (2-4) and 2) Clean the blueing off the crankshaft and
bearing inserts and identify them if them if bearings.
they are to be re-used.
3) Checking main bearing running
g) Lift the crankshaft from cylinder block and
clearance.
remove the bearing inserts.
4) Install the upper bearing halves.
2. INSPECTION AND REPAIR 5) Place the crankshaft in position.
a) Clean all parts in a suitable solvent and dry 6) Lay a length of plastigauge along the
with compressed air. crankshaft journals.
b) Discard the front and rear oil seals. Discard 7) Fit the bearing lower halves to the
all gaskets and remove any gasket material bearing caps and assemble the caps to
remaining on mating faces. the crankcase.

e) Fit the capscrews and tighten to the torque

detailed in SPECIFICATIONS. Do not rotate
the crankshaft.
f) Remove the bearing caps and measure the
thickness to which the plastigauge has been
crushed. This thickness should be as
detailed in SPECIFICATIONS. PILOT
BEARING 51
g) If the clearance is excessive, it may be
necessary to grind the crankshaft and install
undersize bearings. These bearings are
available in sets of +0.76mm and +0.38mm.
See para. 3c for details of re-grinding
crankshaft.
Fig. 5
4. CHECK THE CRANKSHAFT END FLOAT
a) Assemble the crankshaft with the main
bearings in position.
b) Lever the crankshaft towards the front of the
engine so that the thrust face is tight against
the rear thrust flange of the rear main
bearing.
NOTE : Bearing cap bolts should be slackened off
slightly to facilitate this operation.
If the clearance is excessive the rear main
bearings must be replaced.
D. THE CRANKSHAFT
1. Examine the journals for excessive scoring.
2. Measure the diameter of each journal at
various points to check any out of round Fig. 6
tendencies. If the journals are excessively
worn it will be necessary to re-grind the 5. Ensure that the oilways in the crankshaft are
crankshaft and fit undersize bearings. Limits clear.
for undersize grinding are given in fig. 7.
NOTE : Maximum allowable taper on crank pins and 1. REMOVAL
journals is 0.003mm per of length. Crank
a) Place the special tool (3-6) into the insert
pins and journals must be polished and must
and turn in an anti-clockwise direction. Never
not be more than 0.003mm out of round.
re-use an insert which has been removed.
Run-out on centre main bearing journals
must not exceed 0.02mm, total indicator
reading with the shaft mounted on V blocks 2. INSTALLATION
at the front and rear journals. a) Fit a new insert (2-6) into the driver (1-6)
3. Examine the clutch shaft pilot bearing for with the driving lug to the bottom.
excessive wear or corrosion. If necessary b) Screw the insert into the tool guide until it
pull the bearing from the crankshaft and is flush with the end of the tool.
replace with new. c) Place the inserting tool over the tapped hole
4. Examine the flywheel dowels for wear and in the crankcase and turn the handle in a
looseness of fit. If necessary press in new clockwise direction until the insert leaves the
dowels to the dimensions shown in fig.5. tool. Care must be taken not to drive the insert
in too deeply (refer to SPECIFICATIONS).

3. INSTALLATION NOTE : When correctly positioned, the main bearing

a) THE MAIN BEARINGS AND CRANKSHAFT half will stand out 0.79mm either side above
the cap surface and engage inside the
1. Wipe clean the upper bearing half supports
crankcase half bore. Failure to position
in the crankcase, wipe the bearing faces
correctly will result in bearing halves being
with oil and install the upper bearing halves
out of line when cap bolts are torqued down.
with the locating nibs in position.
6. Press a new oil seal into the rear oil seal
52 2. Wipe the crank pins and journals clean and
retainer with the help of special service tool
lay the crankshaft in position.
3. Coat the lower bearing halves and caps in
oil and assemble the bearings to the caps.
4. Install the bearing caps and bearings in their
correct positions and secure with the
capscrews. Tighten the capscrews to the
torque detailed in SPECIFICATIONS and
install the lockwires if the capscrew heads
Fig. 6a
are drilled.
NOTE : If it is necessary to replace one of the
bearing cap capscrews with a “Place” bolt,
both must be replaced as the heads of
“Place” bolts are not drilled.
5. Pull the connecting rods down on to the
crankshaft, lubricate the bearing faces and
assemble the caps in the correct positions.
Secure with the capscrew, tightening them to
Fig. 6b
the torque detailed in SPECIFICATIONS.
DIM STANDARD 0.25mm U/S 0.4mm U/S 0.5mm U/S 0.75mm U/S
1. 53.96 53.71 53.59 53.46 53.21
53.99 53.74 53.61 53.48 53.21
2. 44.45 44.20 44.07 43.94 43.69
44.47 44.21 44.09 43.96 43.71
3. 33.38 33.50 33.57 33.63 33.53
33.43 33.54 33.62 33.68 33.81
4. 61.47 61.52 61.57 61.57 61.57
61.77 61.87 61.87 61.93 61.95
5. 3.18 31.18 3.18 3.18 3.18
3.43 3.43 3.43 3.43 3.43
6. MUST BE CONCENTRIC WITHIN 0.004” T.I.R.
7. These holes must be clean and free of chips and burrs after grinding. Remove sharp edges.
8. 33.35 33.43 33.55 33.60 33.73
33.45 33.58 33.66 33.71 33.83
Permissible width of all Main Journal and Crank Pins except at No. 5 Journal ‘C’ listed above.
Fig. 7
Undersize Limits for Crankshaft Regrinding

MST-H1-EN-3 (fig-6a & 6b) as followed lip GENERAL :

towards the front of the engine. The seal After the installation of new sleeves, pistons or piston
must be pressed hard against the shoulders rings, the engine must be run-in before being operated
of the retainer to ensure squareness. at full speed and load. The first phase of running-in
7. Use jointing compound and fit a new must be gentle enough to prevent excessive pressure
horseshoe gasket to the rear face of the and temperatures. But too gentle operation may result
crankcase, lining up the holes in the gasket in cylinder wall glazing due low combustion
with the bolt holes. temperatures. Improper running-in procedure may result 53
8. Apply a light coating of grease to the oil seal in shorter engine life, loss of power and high oil
and fit it over the end of the crankshaft, consumption. See page 13 for details of run-in.
taking care not to damage the lip of the seal.
Use a seal assembly sleeve for this
operation if possible. Ensure that the garter 1. PREPARATION :
spring is fitted and in position. Locate the Check and fill the cooling system. Check the level
retainer on the dowels. of oil in the crankcase. Bleed the fuel system
9. Fit the five retainer bolts and tighten to the using the hand primer pump located in the fuel
correct torque by stages to ensure even injection pump. Screw out the knurled knob of the
seating on the gasket. hand primer pump until the plunger can be
NOTE : The bottom face of the retainer, after operated. Open the air vent screw on the pre-filter
assembly, must align with the face of the stage and operate the plunger until a constant
crankcase within 0.5mm stream of bubble-free fuel emerges. Tighten the
air vent screw. Open the micro-filter stage air vent
10. Trim the rear oil seal retainer gasket flush
screw and repeat the procedure till a stream of
with the bottom of the crankcase.
bubble-free fuel emerges. Loosen the fuel inlet
11. Assemble the flywheel to the crankshaft (a connection on the injection pump and operate the
& b) chapter 6 - para c. hand primer until all the air is displaced. Tighten
12. Assemble the crankcase front cover (refer the connection. Turn the engine flywheel for one
to chapter 5 para 4). half revolution and repeat the above operation to
13. Install the lubricating oil pump (refer to ensure complete scavenging. Loosen one of the
chapter 4 para B-7). connections of the high pressure fuel injection
14. Use a new gasket and assemble the pipes at the injector end. Turn the engine flywheel
crankcase oil pan. until fuel flows from the pipe. Tighten the
connection and repeat the operation on the other
15. Fill the crankcase with the correct grade of
three pipes. Start the engine and run with the fuel
oil to the level mark on the dipstick.
rack at 1/4 position until the engine attains the
operating temperature.
CYLINDER BLOCK
INSPECTION & REPAIR :
Thoroughly clean the cylinder block. Remove the oil 2. DISMANTLING
sludge deposits on the inner surfaces of the cylinder a) Remove the crankshaft spin-on and clutch
block. Remove the old gasket materials from the shaft pilot bearing if inspection proves this
cylinder head, thermostat, water pump, rear oil seal, necessary.
oil pan and oil filter mating faces. Check the cylinder
b) Remove the oil seal from the rear oil seal
head mating face for warpage using a straight edge
retainer.
and a feeler gauge. If inspection proves it necessary,
remove the studs and cylinder head guide dowels.
While installing the cylinder head guide dowels, 3. INSPECTION AND REPAIR
ensure that the dowel projects 5.85 mm above the
a) Check the main journals and crankpins for
face of the block. Clean the lubricating oil galleries
wear and taper. Grind if necessary to the
using wire brush. While installing expansion plugs,
dimensions shown in Fig. 7.
ensure that shellac/sealer is present around the edges
as well as inside the plugs. b) Check the dowels for wear or damage,
CONDITIONING SCHEDULE replace if necessary pressing into the
dimension shown in Fig. 5.

c) Check the clutch shaft pilot bearing for wear (k) Install the oil pump as detailed in chapter 4
or damage, replace if necessary pressing into para 2c, B-3.
the dimension shown in Fig. 5. (l) Invert the engine.
d) Check that the oilways are clear. (m) Install the crankcase front cover as detailed
in chapter 5, para 2d, B4.
4. ASSEMBLY
a) Install the clutch shaft pilot bearing if it was E. HELI-COIL THREAD INSERTS
54
removed. 1. REMOVAL
b) Install the dowels if they were removed. a) Place the extractor into the insert and turn
c) Install a new key and the crankshaft spin- in an anti-clockwise direction.
on if they were removed.
d) Press a new oil seal into the rear oil seal 2. INSTALLATION
retainer with the lip toward the front of the NOTE : Never use an insert that has been removed.
crankcase. The seal must be pressed hard
a) Place a new insert in the driver with the
against the shoulders of the retainer.
driving lug to the bottom.
b) Screw the insert into the tool guide until it
5. INSTALLATION is flush with the end of the tool.
a) Install the upper half bearing inserts and c) Place the driver over the tapped hole and
lubricate them. turn the handle clockwise until the insert
b) Carefully install the crankshaft and spin it by leaves the tools, then break off the driving
hand. lug. Ensure that inserts are driven into the
c) Install the main bearing caps as detailed in specified depth.
para C-3 ops. (b) to (k).
d) Install the connecting rods, connecting rod FUEL INJECTION PUMP
bearings and bearing caps to the crankshaft 1. REMOVAL :
with the identification numbers to the F-1
Remove the injection pump gear. Remove the four
pump side then tighten the bolts to the
bolts and washers securing the pump to the front
specified torque.
cover. Pull out the injection pump along with the
e) Check the connecting rod side clearance to adapter.
specifications.
f) Use jointing compound and fit a new 2. INSPECTION & REPAIR :
horseshoe gasket to the rear face of the For servicing the fuel injection pump, contact
crankcase lining up the holes in the gasket BOSCH dealer/service. Test specifications -
with the bolt holes. charts are given for your reference only.
g) Apply a light coating of grease to the oil seal
and fit the oil seal retainer over the end of 3. INSTALLATION :
the crankshaft taking care not to damage the Reverse the removal procedure. Ensure that the
lip of the seal. If possible use a sleeve for timing marks on the gears are properly set.
this operation. Ensure that the seal garter 4. ADJUSTMENTS :
spring is in position.
After installing the fuel injection pump, spill cut-
h) Locate the retainer on the dowels, install the off operation has to be done in order to ensure
bolts and to ensure even seating of the proper injection timing. For carrying out the spill
gasket, tighten the bolts by stages to the cut-off operation, the following equipments are
specified torque. necessary.
NOTE : The bottom face of the retainer, after i) External Fuel Pumping Unit
installation, must be in line with the bottom
ii) Swan Neck tube
face of the crankcase with in 0.5mm.
To get the piston to T.D.C. or B.D.C. make use
i) Trim the horseshoe gasket flush with the
of special service tool MST-H1-EN-4 (fig-9 & 10)
bottom of the crankcase.
as follows :
(j) Install the flywheel as detailed in para B-3.

etched mark on the rim of the crankshaft pulley

coincides with the T.D.C. marker fixed on the
cylinder block. Remove the high pressure pipe
connecting the No.1 injection nozzle to the No.1
fuel pump unit. Remove delivery valve from the
No.1 pumping unit and fit the swan neck tube.
Connect the external fuel pumping unit to the fuel
overflow port in the fuel injection pump. Loosen 55
the four bolts securing the fuel injection pump so
that the fuel injection pump body can be rotated
about the pump camshaft axis. Prime the external
fuel pumping unit so that a steady stream of fuel
issues through the swan neck tube. Rotate the
Fig. 8
fuel injection pump body slightly about it’s
camshaft axis. At a particular position, the stream
of fuel will start dripping and finally stop. Tighten
the four bolts to secure the fuel injection pump
at this position. Remove the swan neck tube and
install the delivery valve and the high pressure
pipe.
NOTE : The fuel injection pump of this engine is
pressure lubricated by the engine lubrication
system. The fuel injection pump camshaft
chamber is connected to the engine main oil
Fig. 9 gallery.
4.2 TORQUE LOADING (TORQUE TIGHTENING CHART)

Newton Meter
1. Cylinder head bolts 81 - 88
2. Connecting rod bolts 47 - 54
3. Crankshaft main bearing caps
New cap / New bolt 128.8 - 135
Old cap / Old bolt 108 - 115
Old cap / New bolt 108 - 115
4. Rear oil seal retainer bolt 36 - 42
5. Idler gear shaft bolt 101
6. Nozzle body stud 40 - 47
Fig. 10 7. Nozzle body nut to stud 21 - 27
Hold the tool firmly. 8. Flywheel bolt 88 - 94
Place it over crankshaft pulley nut correctly. 9. Adapter spigot fixing nut 58 - 67
10. Tappet adjusting nut 27 - 33
Then rotate the crankshaft with the wrench for
bringing crankshaft at desired position. 11. Valve housing cover nut 27 - 33
NOTE : This wrench is to be used only for rotating 12. Crankcase drain plug 47 - 54
the crankshaft during tappet adjsutment. Do 13. Camshaft thrust plate 47 - 54
not use the tool for tightening or loosening 14. Front pulley nut 305 - 339
the crankshaft pulley nut. 15. Starter motor bolts 47 - 54
Set the No.1 piston at the T.D.C. on the 16. Injection pump bolt 25 - 28
compression stroke by 4 inlet valve is just 17. Injection pump gear bolt 25 - 28
beginning to open and the No. 4 exhaust valve 18. Rocker arm center bracket 81 - 88
is just beginning to close. Rotate the flywheel a
19. Rocker arm end brackets 40 - 50
little, in the opposite direction, so that the acid
20. Generator pulley nut 34 - 40

CHECKING COMPRESSION manner and let it run at medium speed for about five
Use compression gauge to check compression in all minutes. Closely observe the engine to see that all
four cylinders of the engine individually. (It is advisable parts work freely and the engine operates smoothly.
to check cylinder compression before overhauling. Check the oil pressure.
Comparison of these figures will disclose errors or
With the engine stopped check the crankcase oil level
show improvements.)
and make sure the pressure feed lubrication functions
To check the cylinder compression, screw in a plug properly and no bearing is starved. Restart the engine
56 port adapter in place of the injector of the respective and let it run at medium speed for approximately one
cylinder and connect with compression. Draw up both hour.
connections tight.
If new cylinder sleeves and pistons were installed it
Close the vent valve of the compression gauge and is necessary to run-in for another hour during which
crank the engine briefly by means of the starting the engine is accelerated to full speed for short
motor. Only a few cycles of the engine are required periods.
to obtain a satisfactory reading. After taking the
Closely observe the engine during the running in time
reading retard the pointer on the dial all the way by
and note any faults for later correction.
opening the vent valve. Close the valve again and
repeat the check to make sure that the reading is When time is up, stop the engine and readjust as
correct. follows:
Check compression in all four cylinders of the engine Retighten injection nozzle stud nuts.
as described above. The compression shown on the Check fan belt tension.
gauge is 17.0483 kg/cm2 each graduation mark being Check oil in engine crankcase.
2 kg/cm 2 . With the engine warmed up, normal Draw up all bolts and nuts in accordance with the
compression in the cylinders is 16.5 - 18.5kg/cm2 at tightening torques.
the speed of 100 r.p.m. (starting motor speed).
Check for evidence of oil leakage and inspect all
Compression pressure should be nearly equal in all hose and pipe connection for leaks.
four cylinders of the engine. When a reading is taken
Correct faults observed during the running-in time.
that deviates considerably from the above
specifications, as for example 14.5kg/cm2 and below, Finally, a trial run is made to test chassis and
the cause must be determined and the trouble transmission.
remedied. This trial run should last at least 15 minutes and
Check for leaking valves, faulty piston rings and worn consist of the following tests:
pistons or cylinder sleeves. Testing the engine clutch.
Testing the five forward speeds and the reverse
RUNNING-IN AFTER OVERHAULING speed.
A completely overhauled tractor should undergo a Testing the steering.
thorough check over before leaving the service Testing the brakes.
station. Testing the electrical system.
Make sure that all parts are properly installed and Make a final test with tractor under load.
all bolts are drawn up tight. Carefully inspect all units,
It is important that faults revealed by these tests be
check adjustments as far as accessible and correct
remedied without delay.
if necessary. Remember, it is better to check three
times than commit one error. After an overhaul every part or unit of the tractor
should function properly and be up to the standards
Fill the transmission case with specified lubricant and
and requirements described in the various sections of
grease the tractor liberally in accordance with the
this manual. Only then can you expect ready and
details given in the “Operators Manual”. Be sure that
efficient performance and trouble-free operation the
all instruments and controls function properly before
year round.
preparing the engine for running-in.
Fill the engine crankcase, the fuel injection pump and
the governor housing with specified lubricant. Fill the
cooling system.
Fill the fuel tank with Diesel fuel and vent the fuel
system properly. Start the engine in the conventional

Engine - Turbocharger
57
Chapter-7 Turbocharger
Description
Turbocharger Dismantling
Handling Turbocharger
Instructions on Turbocharger
Turbocharger Service

Engine - Turbo Charger (Chart)
58

DESCRIPTION turbocharger to fail & may cause engine failure.

Function of Turbocharger Dismantling the Turbo Charger
In any given engine, power output is determined by 1. Remove the four Bolts on the exhaust manifold.
the amount of fuel that can be burnt in a given time. 2. Disconnect Oil pressure pipe.
For proper combustion, the fuel needs an adequate
3. Disconnect Oil return pipe by removing 2 bolts
supply of air so therefore for increased power, more
air is required. 4. Disconnect Stub pipe.
5. Disconnect Hose assembly. 59
Since the volume of engine cylinders is fixed, the
air supply can only be increased by using some form 6. Seal the exhaust end of the Turbo and intake
of compressor. The Turbocharger increases the air of the turbo
supply by means of a compressor driven by a turbne Procedure for Handling Turbo Charger
mounted on the same shaft. The turbine is driven b 1. Remove the turbocharger safely and ensure for
the waste exhaus gases. no damgages on it.
Since in a turbocharged engine the exhaust gas 2. Place the turbocharger in some clean place or
energy is used t improve the overall efficiency of the bin free of dirt and dust.
engine, the specific fuel consumption is redused
3. Cover all the inlets and outlets (compressor
resulting in LOWER operating costs.
cover inlet, compressor cover outlet,
There are further advantages like damping the turbine housing inlet, turbine housing
pulses of the exhaust gases, the turbocharge outlet, central housing oil inlet, central
behaves as an effective silencer. Because the air housing oil outlet) of the turbocharger with
supply is maintained under a wide range of engine protection caps, Sticking tapes / sticking plaster
operating conditions, exhaust smoke is generally / polythene sheet covered with rubber bands
reduced. can also be used.
In addition, the turbocharger automatically 4. Ensure that covering material is free of dust
compensates for reduction in power which occurs at / dirt and any loose objects.
higher altitudes.
5. Before mounting the turbocharger, check the
air and oil filter systems of the engine, and
Turbine end Compressor end change the filters alongwith the oil.
6. Examine and / or clean the engine intake and
exhaust manifolds, Foreign matter in the
manifold is bound to cause damage during
start-up. The oil feed and oil drain lines should
be examined, cleaned or replaced.
7. Fill up the oil feed-hole of the turbocharger with
clean engine oil, in order to ensure perfect
lubrication during start-up.
8. Fit the turbocharger, using new bolts and
flange gaskets. As a rule, the connecting Bolts
/ Nuts for fixing the turbine housing are heat
resistant. Use only bolts / nts of suitable
specification.
TURBO CHARGER 9. Start the engine and idle for approx. 2-3
minitues before applying load.
Handling the Turbo Charger 10. After start-up, check the all air, gas and oil line
connections are tight.
While doing maintenance check or repair work on the
engine, if it is ever required to remove the turbocharger 11. Never allow the turbocharger to be opened by
from damages & exposure to any susceptible entries non professional. In case of a problem get the
inside the turbocharger, as these will ensure turbocharger examined by authorised M&M
dealer.

Instruction on Turbocharger Turbocharger Service

During starting : Loss of Power, excess smoke, high fuel consumption,
1. After starting the engine allow it to run at low overheating, high exhaust temperatures, oil leakage
idle for 1 minutes. observe the oil pressure from the turbocharger are all symptoms that coud
gauge, the pressure should be minimum 1kg/ indicate turbocherge malfunction. However, this
sq.cm at 750 rpm. problems can also occur if the engine malfunctions,
hence check the engine thoroughly.
60 During Stopping
NOTE : In case problem is on account of
2. Never put off the engine immediately after the
turbocharger, do not touch the turbo
Tractor is stopped. Allow it to run at low idle
charger and get it attended only through
for 30 secs. observe the oil pressure gauge,
Authorised Mahindra Dealer.
the pressure should be minimum 1kg/sq.cm
at 750 rpm.
During Running :
1. During Operation of the Tractor, never allow the
oil pressure to fall below 1kg/sq.cm. In case
the oil pressure drops below 1kg/sqcm, stop
the Tractor and get the cause rectified before
attempting to restart the Tractor.
2. Periodically discharge the unloader valve to
ensure that the dust is being discharged.
During Maintenance
1. Never dismantle the Turbocharger components
while dismantling the engine. Always get it
checked /repaired/overhauled through
authorised M & M dealer.
2. All dust enrty points in the air intake system of
the engine to be carefully monitored. The dust
ingress in the turbocharger is to be totally
avoided. All the hoses to be checked for cracks
and to be replaced, if necessary.
3. Air cleaner primary element should be cleaned
at every 250 hrs of operationor or glowing of
choke indicator on dash board or when audible
warning is given by hooter.
4. Replace the primary element after 3 cleanings
or 750 hrs (whichever is earlier)
5. Replace the safety element at every 2250hrs or
after 3 replacements of primary element
whichever is earlier.
6. Use genuine parts during replacement like
primary paper element of dry air cleaner, lube
oil filter.
All the above instructions have to be followed,
failing which the life of the turbocharger will be
reduced considerably and may also invalidate the
warranty.

Engine - Tune-Up
ENGINE TUNE-UP 10. ELECTRICAL CONNECTIONS

(a) GENERAL a. Check all wiring in the starting circuit for looseness
The following steps outline the operations in an engine at connections or corrosion.
tune-up. These steps point out the parts of the engine 11. COOLING SYSTEM
to be cleaned, checked, timed or repaired. a. Flush the radiator with clean water, then drain and
1. INJECTION PUMP refill with antifreeze solution.
a. Remove the injection pump from the engine and b. Check for loose hose clamps, or defective hoses. 61
run a calibration test. c. Check the water pump for leaks, replace the seal
b. Check the injection pump timing. if necessary.
2. INJECTION NOZZLES d. Check the fan belt for wear and correct
a. Remove the injection nozzles and check for adjustment.
leaks, opening pressure and correct atomisation. 12. COMPRESSION PRESSURE
Adjust or replace if necessary. a. Remove the injector nozzle holders from the
3. ENGINE SPEED CONTROL cylinder head.
a. Check the operation of the hand control lever to b. Install a suitable compression tester in the No.1
ensure that all linkage is free and that full travel cylinder
of the hand lever corresponds with the governor c. Crank the engine using the starter motor, until
control lever. the gauge shows a constant reading. Compare
b. Check the engine r.p.m. with a tachometer or this figure with that given in SPECIFICATIONS.
“Strobotorch”. d. Repeat the test for each remaining cylinder.
c. Adjust low & high idle speeds to specifications. NOTE : Ensure that the batteries are in a fully
4. VALVES charged condition before starting this test.
a. Check the clearance of the intake and exhaust
e. The variation of pressure between cylinders
valves and adjust if necessary.
should not exceed 3.5 kg/cm2. Greater variation
5. AIR CLEANER indicates the need to make repairs. If the
a. Check the air cleaner and connections for compression reading rises often putting some
possible leaks. engine oil on top of the piston, worn rings are
b. Clean the pre-cleaner. indicated, if the compression doesn’t increase,
a value leak or other leak is indicated.
c. Clean the oil cup and detachable element. Fill
the cup to the correct level with clean oil.
6. FILTERS
a. Clean the lubricating oil filter case and install a
new element.
b. Replace the element in the fuel filter.
7. WATER TRAP
a. Remove the water trap. Clean thoroughly and
inspect the screen for damage.
8. ALTERNATOR
a. Check the brushes for sticking or uneven wear
and correct accordingly.
b. Inspect the commutators. Clean and undercut the
insulators if necessary.
9. STARTER MOTOR
a. Check the brush gear for sticking or uneven wear
and correct accordingly.
b. Inspect the commutator, clean if necessary.

Engine - Trouble Shooting
TROUBLE SHOOTING
Much can be learned about the condition of an engine if a good visual inspection is performance before the
actual cleaning operations begin.
After cleaning, the exterior of the engine should once more be inspected carefully and a note made of any
parts such as brackets, covers, etc., that are bent, broken, rusted or missing completely. The crankcase or
cylinder block should be checked for evidence of freezing around core plugs or for actual breaks in the water
jacket.
62
Probable Cause Remedy
Engine Fails to Turn

1. Batteries too low to turn engine - - - - - - - - - - - - - - Charge batteries or install new ones.
2. Starting switch inoperative - - - - - - - - - - - - - - - - - - Inspect for faulty cables an terminals. Replace starting
switch if necessary.
3. Cranking motor inoperative - - - - - - - - - - - - - - - - - Refer to Service Manual ‘Electrical Equipment”.
4. Engine oil too heavy - - - - - - - - - - - - - - - - - - - - - - Use correct grade of lubricating oil as specified in the
operator’s manual.
5. Internal seizure - - - - - - - - - - - - - - - - - - - - - - - - - - Hand crank the engine. If the engine does not turn
easily, seizure due to internal damage; including gear
train, pistons, sleeves, connecting rods or main
bearings, is indicated.
6. Hydrostatic lock - - - - - - - - - - - - - - - - - - - - - - - - - - Remove all the injection nozzles and crank the engine.
Check for fuel or coolant in the cylinder.
Engines Does Not Start /

Engine Start But does not Develop Full Power
1. Low or no fuel pressure
a. Insufficient fuel - - - - - - - - - - - - - - - - - - - - - - - - Check fuel tank.
b. Fuel oil filter clogged - - - - - - - - - - - - - - - - - - - - Replace filters.
c. Fuel filter gaskets defective
c. (air being drawn into fuel) - - - - - - - - - - - - - - - - Replace gaskets.
d. Moisture in fuel tank - - - - - - - - - - - - - - - - - - - - Drain entire system including water trap and filter. Refill
with clean fuel, and vent the air from the system.
2. Poor fuel - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Use a good grade of fuel.
3. Air cleaner clogged - - - - - - - - - - - - - - - - - - - - - - - Remove and service air cleaner as described in
operator’s manual
4. Injection pump not properly timed
to the engine - - - - - - - - - - - - - - - - - - - - - - - - - - - - Check timing. (Refer to Section “INJECTION PUMP”.)
5. Fuel line clogged or air in line - - - - - - - - - - - - - - - Clean fuel line and vent fuel system. Refer operator’s
manual.
6. Injection pump not operating properly - - - - - - - - - Remove injection pump and test it. Refer to Service
Manual “Fuel System” for test specifications.
7. One or more fuel injection nozzles
not operating properly - - - - - - - - - - - - - - - - - - - - - Replace the injection nozzles.
8. Loose or broken fuel lines or fittings between
injection pump and injection nozzles - - - - - - - - - - Tighten or repair.
9. Loose or broken connections or leaking gaskets
at intake manifold or exhaust manifold - - - - - - - - - Tighten or repair.
# - If Provided, § - See Mahindra Tractor Dealer / Authorised service centre

10. Improper valve settings - - - - - - - - - - - - - - - - - - - - Reset as necessary. If out of adjustment an

excessive amount, check for bent push rods.
11. Lack of compression - - - - - - - - - - - - - - - - - - - - - - Refer to “Poor Compression”
Engine Turns But Will Not Start 63

1. No fuel delivery to injection nozzles - - - - - - - - - - - Check fuel supply, air in system, plugged filter elements
and injection pump.
2. Intake or exhaust system clogged - - - - - - - - - - - - Remove air flow restriction and clean exhaust system.
Service the air cleaner.
3. Improper adjustment on pump linkage
and controls - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Readjust as necessary.
Poor Compression
1. Piston rings worn, broken or cracked - - - - - - - - - - Install new rings.
2. Cylinder sleeve worn - - - - - - - - - - - - - - - - - - - - - - Install new sleeves.
3. Valves damaged or worn - - - - - - - - - - - - - - - - - - - - Install new valves.
4. Broken valve spring - - - - - - - - - - - - - - - - - - - - - - - Install new springs.
5. Worn cylinder head gasket - - - - - - - - - - - - - - - - - - Install new gasket.
6. Valve seats worn or cracked - - - - - - - - - - - - - - - - - Grind valve seats. If cracked, install new valves.
7. Worn pistons - - - - - - - - - - - - - - - - - - - - - - - - - - - - Install new pistons.
8. Excessive valve guide wear - - - - - - - - - - - - - - - - - Install new valve guides.
9. Sticking valves or bent valves stems - - - - - - - - - - Free stem and correct cause. Replace valves with bent
stems.
10. Faulty valve action - - - - - - - - - - - - - - - - - - - - - - - - Adjust valve clearance.
Engine Overheats
1. Water pump air bound - - - - - - - - - - - - - - - - - - - - - Vent air from water pump and thermostat housing.
2. Insufficient coolant in cooling system - - - - - - - - - - Check level and add if necessary. Check hose
connections for leaks.
3. Dirt & trash on outside of Radiator - - - - - - - - - - - - Clean between the tube fins with air or water pressure.
4. Cooling system clogged - - - - - - - - - - - - - - - - - - - - Drain and flush cooling system.
5. Hose connection leaking or collapsed - - - - - - - - - - Change hose.
6. Insufficient oil - - - - - - - - - - - - - - - - - - - - - - - - - - - - Maintain proper oil level.
7. Engine oil diluted with fuel - - - - - - - - - - - - - - - - - - Change oil. Inspect for loose fuel line connections on
the injection nozzles. Check for defective injection pump.
8. Radiator cap not sealing or defective - - - - - - - - - - Replace
9. Defective thermostat - - - - - - - - - - - - - - - - - - - - - - Remove and test thermostat. Replace if necessary.
10. Water pump defective - - - - - - - - - - - - - - - - - - - - - - Repair pump.
11. Clogged oil filter - - - - - - - - - - - - - - - - - - - - - - - - - - Replace oil filter element.
12. Fan belt slipping - - - - - - - - - - - - - - - - - - - - - - - - - - Adjust belt tension.
13. Engine overloaded - - - - - - - - - - - - - - - - - - - - - - - - Reduce load.
14. Cylinder head gasket/leaking - - - - - - - - - - - - - - - - - Install new head gasket properly using sealing compound.
15. Turbocharger# malfunctions - - - - - - - - - - - - - - - - - - §

Engine Misses on One or More Cylinders

1. Insufficient air to engine - - - - - - - - - - - - - - - - - - - - Remove and clean air cleaner and air cleaner pipe.
2. Defective injection nozzles - - - - - - - - - - - - - - - - - - Replace with serviceable unit.
3. Air lock in the injection pump or fuel filter - - - - - - - Vent air from system and check all fuel lines and
64 connections for leaks.
4. Poor fuel - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Use good grade of fuel.
5. Air leaks around intake manifold - - - - - - - - - - - - - Remove and install new manifold gasket.
6. Injection pump not operating properly - - - - - - - - - Remove injection pump and test it.
7. Injection pump not properly timed to
the engine - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Check and adjust timing if necessary.
Excessive Oil Consumption

1. Piston rings worn or broken - - - - - - - - - - - - - - - - - Install new rings.
2. Oil level in crankcase too high - - - - - - - - - - - - - - - Maintain proper oil level.
3. Crankcase oil pan gasket leaking - - - - - - - - - - - - Install new gasket.
4. Worn valve guides - - - - - - - - - - - - - - - - - - - - - - - - Install new valve guides.
5. Cylinder sleeves worn - - - - - - - - - - - - - - - - - - - - - Install new sleeves.
6. Front and rear crankshaft oil seal leaking - - - - - - Install new oil seals.
7. Piston rings not seating - - - - - - - - - - - - - - - - - - - - Install new rings.
8. Clogged oil ring - - - - - - - - - - - - - - - - - - - - - - - - - - Remove and inspect and, if necessary, replace.
9. Oil pan drain plug loose or worn - - - - - - - - - - - - - Install new drain plug and gasket tighten plug.
10. Overheating - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Refer to “Engine Overheats” on preceding page.
11. Excessive oil poured into crankcase - - - - - - - - - - Drain oil and fill to correct level only.
12. Wrong specification oil used - - - - - - - - - - - - - - - - Intall oil meeting specifications in the operator’s manual.
13. Air cleaner clogged - - - - - - - - - - - - - - - - - - - - - - - - Disassemble & clean air cleaner.
Engine Does Not Idle Properly

1. Injection Nozzle defective - - - - - - - - - - - - - - - - - - - Test Nozzle and repair and reset as per MICO.
2. Restriction to fuel delivery or leaking
fuel lines - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Inspect fuel lines and valves; inspect for proper level
in fuel tank.
3. Poor compression - - - - - - - - - - - - - - - - - - - - - - - - See poor compression problems.
4. Slicking valves - - - - - - - - - - - - - - - - - - - - - - - - - - - See valuse sticking problem.
5. Improper adjustment of injection pump
linkage and controls - - - - - - - - - - - - - - - - - - - - - - - Readjust
4. Valve and spring assembly in operative - - - - - - - - Repair and install parts needed.
Engine Knocks
1. One or more cylinders misfiring - - - - - - - - - - - - - - Locate and correct cause. Disconnect the injection lines
at the valve housing one at a time and check for rpm
drop of each cylinder.

2. Loose connecting rod - - - - - - - - - - - - - - - - - - - - - - Tighten connecting rod.

3. Poor grade of fuel, or water in fuel - - - - - - - - - - - - Use good grade of fuel and check for water in fuel.
4. Incorrect engine temperature - - - - - - - - - - - - - - - - - Keep temperature in work range of heat indicator. Check
thermostat for proper operation.
5. Injection pump timing not correct - - - - - - - - - - - - - Time the injection pump correct. Refer fuel injection 65
system manual.
Excessive Smoke
1. Air cleaner clogged - - - - - - - - - - - - - - - - - - - - - - - Service air cleaner as described in the operator’s
manual.
2. Too much oil in Air cleaner - - - - - - - - - - - - - - - - - Remove air cleaner and remove excess oil.
2. Engine overloaded - - - - - - - - - - - - - - - - - - - - - - - - Reduce load.
3. Improper fuel - - - - - - - - - - - - - - - - - - - - - - - - - - - - Use good grade of fuel.
4. Defective injection nozzle - - - - - - - - - - - - - - - - - - Install new injection nozzle.
5. Worn pistons, rings and sleeves - - - - - - - - - - - - - Install new parts.
6. Incorrect valve adjustment - - - - - - - - - - - - - - - - - - Adjust valves properly.
7. Incorrect injection pump timing - - - - - - - - - - - - - - Time injection pump Refer Group
8. Leaking manifold gaskets - - - - - - - - - - - - - - - - - - - Install new gaskets.
9. Incorrect lubricating oil - - - - - - - - - - - - - - - - - - - - - Use grade of oil specified in operator’s manual.
Bearing Failure
1. Low oil level - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Maintain proper oil level.
2. Lack of oil - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Maintain proper oil level.
3. Engine runs too hot - - - - - - - - - - - - - - - - - - - - - - - Keep engine at normal operating temperature.
4. Loose bearings - - - - - - - - - - - - - - - - - - - - - - - - - - - Install new bearings.
5. Use of improper lubricating oil - - - - - - - - - - - - - - - Use grade of oil specified in operator’s manual.
6. Foreign materials entering engine - - - - - - - - - - - - - Use clean oil containers when filling engine with oil and
see that there no leaks in ther air cleaner or in the air
induction system.
7. Oil lines clogged - - - - - - - - - - - - - - - - - - - - - - - - - Clean all oil passages.
8. Connecting rod bent - - - - - - - - - - - - - - - - - - - - - - Align rod or install new.
9. Crankshaft out of alignment - - - - - - - - - - - - - - - - - Install new crankshaft.
Valves Sticking
1. Valve springs weak - - - - - - - - - - - - - - - - - - - - - - - Install new springs.
2. Valve springs broken - - - - - - - - - - - - - - - - - - - - - - Install new springs.
3. Gummy deposits from inferior fuel or oil - - - - - - - Clean and use proper fuel or oil.
4. Valve stems scored or carboned - - - - - - - - - - - - - Clean if necessary, install new valves.
5. Insufficient clearance between valve
stem and guide - - - - - - - - - - - - - - - - - - - - - - - - - - Ream valve guides for proper clearance.

Piston and Cylinder Sleeve Wear

1. Oil of unsuitable grade of viscosity - - - - - - - - - - - - Use oil meeting operator’s manual / specifications.
2. Piston rings stuck or broken - - - - - - - - - - - - - - - - - Install new rings.
66
3. Lack of oil - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Keep oil at proper level.
4. Foreign materials entering engine - - - - - - - - - - - - - Inspect and service air cleaner. Proper care of air cleaner
is very important.
5. Piston rings not fitter properly to cylinder - - - - - - - Install new rings and fit properly.
6. Dirty containers used for lubricating oil - - - - - - - - - Lubricating oil must be kept in a clean place and clean
containers used when filling engines.
Improper Fuel Pressure

1. Fluctuating fuel pressure - - - - - - - - - - - - - - - - - - - Inspect fuel injection pump.
2. Fuel pressure too low - - - - - - - - - - - - - - - - - - - - - Check for clogged fuel filter, lines and defective fuel
injection pump.
3. Air leaks on suction side of injection pump - - - - - Tighten fuel lines. Check for defective fuel filter case
gaskets.
Low Engine RPM

1. Governor control linkage binding or damaged - - - Repair and install new parts needed.
2. Governor control rod improperly adjusted - - - - - - Adjust rod to proper length.
Low Fuel Pressure

1. Dirty fuel filters - - - - - - - - - - - - - - - - - - - - - - - - - - Replace filters.
2. Broken fuel lines - - - - - - - - - - - - - - - - - - - - - - - - - Repair or install new line.
3. Clogged line - - - - - - - - - - - - - - - - - - - - - - - - - - - - Clean or install new line.
4. Improper grade of fuel - - - - - - - - - - - - - - - - - - - - - Use correct fuel
5. Air leaks on suction side of injection pump - - - - - Tighten fuel lines. Check for defective fuel filter case
gaskets.

GROUP - 3
Air Cleaner & Fuel System
Chapter 1 - Air Cleaner
Chapter 2 - Fuel System
Chapter 3 - Rotary Fuel Injection Pump
Chapter 4 - Fuel Injection Pump Calibration Chart
1st Version 2nd set.pmd 67 6/3/2006, 11:18 AM

Air Cleaner & Fuel System - Air Cleaner
Chapter-1 Air Cleaner

Description
68
Oil Bath Type Air Cleaner Removal
Oil Bath Air Cleaner Cleaning, Inspection, Repair & Installation
Dry Type Air Cleaner
Dry Air Cleaner Servicing

ONE OF THE TWO TYPES OF AIRCLEANER ARE 3. Clean through the tube with a rag and cleaning
FITTED ON TRACTOR MODEL. rod.
1. Oil Bath / Three stage air filter 4. Inspect the body for leaks.
2. Dry Type Aircleaner 5. Inspect the screens for corrosion.
1. OIL BATH TYPE AIRCLEANER 6. Change the paper filter element (3-1).
A) DESCRIPTION (D) INSTALLATION
All air entering the engine must pass through the 1. Reverse the removal procedure ensuring that the
aircleaner before entering the inlet manifold and detachable element is in position before the oil
cylinders. The pre-cleaner is mounted on the inlet cup, filled to the level mark with the correct grade
tube of the Aircleaner. As the air enters at high oil, is reassembled.
speed through pre-cleaner side inlet and it passes
through a series of angular vanes fitted into the 69
1
inlet induce a rotary motion/cyclonic twist to the
air stream. Centrifugal force, therefore, causes
heavier dust particles and other foreign matter to 10 11
be separated from the air and thrown to the
outside of the tube and fall into the removable dust
collector. The pre-cleaned air then passes to the
oil bath air-cleaner through central tube and
through the oil in the oil sump\bowl of the air- 2
cleaner. Much of the dust and other foreign

material in air is caught in the sump. The air then
9
passes up through the wire mesh/screen
surrounding the central tube, carrying oil droplets
with it. As the air passes through the filter mesh, 12
1. Twin Air Cleaner Cpte.
most of the remaining dust/dirt is deposited on 13 14
2. Housing
the oil-wetted surfaces and drains back into the
3. Paper Element
sump. After passing through the wire mesh the
4. Upper Wire Mesh
air passes through the paper filter element before
5. Grooved Rubber Ring 3
entering the engine.
6. Clamp
B) REMOVAL
7. Lower Wire Mesh
1. Remove the pre-cleaner and exhaust silencer. 4
8. Oil Bowl
2. Raise the hood. 9. Bracket Mounting
3. Loosen the hose clamp at the air cleaner. Clamp 5
10. Rubber Beading-Large 6
4. Unscrew clamp wing bolt and remove the oil cup.
11. Rubber Beading-Small
5 Remove the capscrews which clamps the air 12. Bolt 7
cleaner body support bracket on the engine. 13. Nut
6. Work the air cleaner free of its hose and remove. 14. Washer 8
C) CLEANING, INSPECTION AND REPAIR

1. Cleaning the precleaner - unscrew the wing nut Fig. 1
and remove the top cover. Invert the precleaner
and allow all dust to fall off. Remove the 2. DRY TYPE AIR CLEANER
balance traces of dust / dirt by cleaning the inside The 595 DI Super Turbo is fitted with Dry Type of
of the bowl with a clean cloth. Ensure that the Air cleaner. This new air cleaner is robust in design
rubber ring is not cut or worn out. Replace if & has better dust unloading capability.
damaged. Take care that the rubber ring is fitted A) Frequency of Cleaning :
perfectly to ensure complete sealing. 1) Clean the primary element after every 250 hrs of
2. Remove the detachable element (4 to 8-1) and operation or glowing of choke indiactor on
wash the complete assembly in solvent. dashboard or audible warning given by the hooter.

2) Replace the primary element after 3 cleanings or

750 hours (whichever is earlier)
B) Service Procedure :
1. Cleaning the precleaner - unscrew the wing nut
and remove the top cover. Invert the precleaner
and allow all dust to fall off. Remove the
balance traces of dust / dirt by cleaning the inside
of the bowl with a clean cloth. Ensure that the
rubber ring is not cut or worn out. Replace if
damaged. Take care that the rubber ring is fitted
perfectly to ensure complete sealing.
70 2. Unscrew the wing nut of the mounting bracket of
air cleaner, lift the air cleaner assembly out of the
bracket.
3. Take out the cover after opening 3 nos latch
assembly of the cover.
4. Gently pull the primary element from the housing.
(Do not force to remove the element from the
housing)
5. Clean the primary element by blowing air
(maximum pressure 1.4 kg/cm2) from inside and
outside. If compressed air is not available gently
tap the elemnts from the ends on the tyre.
(Tapping at the centre position may cause
damage to the paper element).
6. After cleaning check the element for any crack/
pin holes/damage by putting a light bulb inside
the element. A new element should be used if 1 Precleaner complete
the element is found defective. Comprising of
7. Use clean cloth to wipe the air cleaner housing, 2 cover top complete
3 ring rubber precleaner complete
cover and sealing areas of the primary element.
4 collector dust
8. Do not remove the safety cartridge during 5 ring rubber precleaner bottom
cleaning. Safety cartridge to be replaced after 6 disc cpte bottom
every three replacements of primary filter or 2250 7 bracket precleaner
8 hose precleaner
hrs whicever occurs earlier..
9 bracket for dry air cleaner mounting
9. Ensure that primary element is fully seated in the 10 air cleaner dry type
housing before putting and latching the cover. comprises of
11 cover
10. Do not use the latches on the cover to force the 12 primary air filter
element into the housing. This will damage the 13 safety air element
element / housing and will void warranty. 14 latch assy (cover to body)
11. Please ensure that unloader valve is always in 15 dust unloader
16 clip dust unloader
downward direction.
17 air cleaner bracket
Additional Precautions : 18 wing nut
19 hose assy air intake
1) While washing the Tractor ensure that the engine
20 hose front (tt)
should not be in running condition as this may 21 metal pipe
lead to sucking of water through air cleaner and 22 hose rear (tt)
cause hydrostatic lock of engine. 23 clips
24 clip hose air cleaner dia.76
2) Do not clean the element by keeping it over
25 clip hose air cleaner dia.54
exhaust silencer. Also do not keep the element 26 spring hose front
on hot engine. 27 spring hose rear

Air Cleaner & Fuel System - Fuel System
Chapter-2 Fuel System

Description
71
Fuel Tank Removal, Cleaning, Inspection & Repair
Bleeding Fuel System
Injectors Removal & Installation
Fuel Injection Pump Lubrication, Removal, Installation & Adjustment

Fig 1. Fuel Tank - NST
72
Fig 2. Fuel Tank - Bhoomiputra
FUEL TANK - NST FUEL TANK - BHOOMIPUTRA

1. Fuel Tank 1. Fuel Tank
2. Float Unit 2. Scuttle Support
3. Fuel Tank Bracket LH/RH

(A) DESCRIPTION 2. Disconnect the fuel pipe at the tap or water

The fuel lank is enclosed within a false outer seperator and disconnect the fuel return pipe.
hood sheet and is integral with it. 3. Raise the hood and remove the nuts and the
The filler cap incorporates an air vent hole and spring washers. Then remove the battery cover
a gasket. plate and retainer.
The tank is rubber mounted on front and rear 4. Disconnect the battery terminals and remove the
scuttle supports which are bolted to the clutch batteries.
housing. 5. Remove the scuttle panel and the filler plate.
The left hand and right hand hood latches are 6. Carefully free the instrument panel. Disconnect
attached to brackets welded to the lower forward the oil pressure pipe from the gauge. If the
false hood sheet section. machine is fitted with a heat indicator, the sensor
heat indicator must be removed from the cylinder 73
At the rear, the scuttle panel, instrument panel
head. Disconnect the hourmeter cable drive at the
and filler plate are all secured to the tank
instrument panel. Lay the instrument panel on the
surrounds. A fuel gauge sender / Tank unit is fitted
right hand foot plate.
on the tank for fuel level gauge.
7. Turn the steering wheel to the full left hand lock
The steering column and governor control rod run
and remove the steering wheel retaining nut and
through a tube in the fuel tank and are enclosed
washer. Remove the steering wheel from the
by the tank surrounds.
keyed taper. It it is necessary to remove steering
(B) REMOVAL wheel
1. Drain the tank completely, through either water
seperator drain cock or fuel tank drain tap.
5
3
Fig.3 Left Hand view of Engine
1. Fuel Filter 3. Feed Pump 5. Water Separator

2. Starter Motor 4. Fuel Injection Pump

8. Remove the two cap screws securing the

governor control bracket to the steering column.
Disconnect the governor lever to cross shaft
control rod and withdraw the governor control lever 2 1
complete with bracket.
9. Remove / disconnect the wire connection from the
Tank unit / Fuel gauge sender if it is fitted.
10. The tank is rubber mounted onto the front and
rear scuttle supports. Free the seven lock washer
tabs and slacken off the securing bolts and
locknuts. Lift the tank upwards and away from the
steering column housing. Remove the lower
74
mounting pads.
(C) CLEANING, INSPECTION AND REPAIR
1. Clean the tank at every 2000 hours thoroughly. Fig.5
2. Check the tank for leaks. 1. Central Bolt of Primary Filter
3. Ensure that the fuel filler cap air vent is open and 2. Central Bolt of Secondary Filter
clean.
2. Loosen the vent screw (4-4) on the secondary fuel
4. Check the ‘Tank unit’ Fuel gauge sender is
filter and operate fuel feed pump hand primer
working properly.
until fuel free of air is flowing. Re-tighten vent
(D) INSTALLATION
screw 4. (see fig. 4)
1. Reverse the removal procedure.
3. Loosen fuel inlet connection on the injection pump
2. Fill the tank with clean fuel and bleed the system and operate the hand primer on the feed pump
in the following sequence. until all air is displaced. Tighten the connection.
(E) BLEEDING FUEL SYSTEM 4. Release the air bleed screw on the injection pump
1. Loosen the vent screw (3-4) on the prefilter and again use the hand primer until all air is
and operate the fuel feed pump hand primer until displaced. Tighten the connection.
fuel free of air is flowing. Re-tighten the vent 5. Repeat operation ‘1’ to expel any air which may
screw 3. have been drawn in.
6. Turn the engine for one half revolution and repeat
item 2 to ensure complete scavenging of transfer
pump.
4 3
7. Loosen the connections on the high pressure
pipes at the injection nozzle. Turn over the engine
until fuel flows from the pipes free of air, then re-
5 tighten the connections.
FUEL TAP (VALVE)

The Fuel Tap is located between the Feed Pipe from
tank to feed pump. The Screw type Valve arid Seal
Assembly has two positions : off and on The fuel is
allowed to flow while the valve is screwed out and vice
1 versa.
2
Remove the fuel cock and blow with compressed air
Fig.4
to clean it. Replace it after cleaning and check for any
leakage.
1. Drain Plug of Primary Fuel Filter
2. Drain Plug of Secondary Fuel Filter FUEL PRE-FILTER/WATER TAP
3. Bleeding Screw of Primary Fuel Filter This Assembly separates any water from the Diesel.
4. Bleeding Screw of Secondary Fuel Filter It is a safe-guard and arrest any dirty contaminated
5. Pump Inlet Pipe fuel-reaching Feed Pump and ultimately the Fuel

Injection Equipment via. Filtering System. The element type. All fuel is fed through the filter
preliminary Filter consists of a Filter Housing, Filtering before passing to the injection pump. The life of
Sleeve, Housing Cover, Helical Spring, Clamp and the filter depends on the amount of impurities it
Knurled Nut. The Pre-Filter shall be cleaned periodically removes from the fuel. Therefore, clean fuel and
after 50 Hours or earlier as per the local conditions. a well-cared-for water trap will not only increase
(See Fig.6) the life of the filter, but also make it more
efficient. Drain plugs are provided to remove dirt
and water.
It is of the bowl type and consists of a head
assembly, replaceable elements and bowls. The
bowls and Head Assembly held together by center
bolt (fig. 4).
75
Two elements are used in the twin bowls of the
filtration system. These two elements are same
for both the primary filter and the final stage filter.
Both primary and final stage Micro (paper) inserts
should not be cleaned but only replaced as
recommended. Refer Operator’s Manual.
If impaired engine operation indicates the filter has
become clogged, replace the filter elements
Fig. 6 - Preliminary Filter Dismantled immediately. The condition will be indicated by
loss of power and engine missing at full load.
1. Knurled nut 4. Housing
2. Clamping yoke 5. Packing ring (b) Removal
3. Wire fabric insert 6. Spring 1. Disconnect all fuel pipes at the filter.
2. Remove the cap screws securing the filter to
(b) Removal the manifold and remove the filter.
(1) Unscrew Knurled Nut (1-6) clamping yoke (2- 3. For replacement of fuel filter element. Refer
6). Operator’s Manual.
(2) Swivel out clamping yoke (2-6) and remove (c) Installation
the filter Housing (4-6). 1. Reverse the removal procedure.
(3) Take out Fabric Insert (3-6) and spring (6-6). 2. Bleed the fuel system. Refer chapter II para
NOTE (1) : If the packing ring (5-6) become hard or ‘e’.
damage, it should be replaced to prevent 5. INJECTORS
air entering the fuel system. a. DESCRIPTION
NOTE (2) : Rinse the insert and housing in petrol or The performance of the modern High speed engine
diesel. depends largely upon proper functioning of its fuel
NOTE (3) : Examine the body for cracks and tap for injection system. For efficient combustion and
freedom of operation. optimum engine performance it is imperative that
NOTE (4) : Do not overtighten the housing as it may the injection nozzles are always in functionally
crack satisfactory condition so that accurately metered
(C) Installation quantities of fuel from the injection pump are
injected into the engine combustion chamber as
(1) Installation is the reversal of the REMOVAL
follows :
procedure.
1. A perfectly atomized condition for proper
(2) Fill the tank with fuel and bleed the fuel
mixing of the fuel with compressed air. The
system.
fuel delivery is exactly timed.
6. THE FUEL FILTER
2. Correct spray dispersion and pattern.
(a) Description
The fuel filter is of the full flow replaceable

pressure and temperatures to the line of

80-90 kg/cm2 and 30000C respectively.
Although the nozzles have been designed to
bear these severe working conditions, the
nozzle needle and body seats affected over
a prolong period of operation. Dribbling,
incorrect opening pressures, improper spray
patterns and leaky nozzles affect the engines
performance. The clearly visible symptoms
are :
1. Smoky exhaust i.e black or in some cases
76 white.
2. Increased fuel consumption.
3. Overheating.
4. Loss of power.
Fig. 7
Cross-Sectional View of Engine 5. Engine knocking, misfiring and uneven
running However, complaints of the above
1. Injector 9. Piston nature may not be solely due to
2. Clamp 10. Liner malfunctioning of the nozzles. Other
3. Cylinder Head 11. Keystone Ring contrutory factors such as poor compression,
4. Valve Seat Insert 12. Bevelled Ring injection timing cooling problems, exhaust /
5. Valve Seal 13. Oil Control Ring intake restriction, Lubrication systems
6. Valve 14. Connecting Rod problems, operating conditions, etc. should
7. Valve Guide 15. Piston Pin also be investigated.
8. Cylinder Block 16. Gasket
6. Fuel filtration.
7. Quality of high pressure pipes.
3. Under proper specified opening pressure and
temperatures. 8. Careless installation of injectors on the
engine.
The injection nozzles are designed to ensure
that fuel injected into the combustion b. INJECTOR NOZZLE REMOVAL
chamber mixes with the compressed air. At 1. Disconnect the high pressure pipes
the end of the injection the nozzles must not connecting the nozzles and injection pump.
only close instantly but completely as 2. Disconnect the fuel leak off pipe assembly
otherwise any after - injection will lead to from the nozzle.
coking and will affect atomization and induce
3. Remove the injector retaining nuts and conical
on irregular exhause beat. Nozzle coking can
washers securing the injector clamps.
also disturb spray from the prescribed
directions. 4. Remove the injectors carefully with special
service tool MST-H1/2-EN-5 as follows
The needle seat of the nozzle body, which
Tighten the puller screw of tool on
is exposed to exceedingly high pressures and
temperatures, must not develop noticeable injectors head.
wear under the constant hammering action of Slide the puller sleeve on puller screw of
the nozzle needle. Therefore we have tool such that it correctly rests on the
increased development of higher speed cylinder head body.
engines, shorter duration of injection and Tighten the nut on the puller screw of tool
higher performance, the stresses on fuel till the injector comes out.
injection equipment in general and nozzles in NOTE : Cover the cylinder head openings and plug
particular. The peak pressure on the fuel the inlet and leak - off openings of injectors
injection system have increased, to between with protection caps.
400-700 kg/cm2. The injection nozzles have
to face constantly fluctuating combustion

Wipe off dirt and loose carbon from each DRAINING WATER FROM WATER SEPARATOR
injector with a cloth and clean the tip with a Check for water level in the water separator and drain
brass wire brush. it when the red band reaches the level mark as
indicated
Fig. 8
77
Fig. 10
Rotate the knob in anticlockwise direction and allow

water to pass throught it, close the knob when water
has been removed.
FUEL INJECTION PUMP
a. Description
Fig. 9
The MICO BOSCH type pump is flange mounted
c. INSPECTION AND REPAIR on the engine with four bolts and spring washers.
It is single acting plunger type pump in which
For inspection and repair of nozzles contact
plunger stroke is constant but the effective working
MICO / Boch dealer / service.
stroke Is adjustable.
d. INSTALLATION b. Lubrication of DI engine fuel injection pump
Reverse the removal procedure using New copper The fuel injection pump of this engine is
washer and tighten to the specified torque. Be pressure lubricated by the engine lubrication
sure that the fuel overflow banjo in the injector system. The fuel injection pump camshaft
is towards the front of the engine. chamber is connected to the engine main oil
After the assembly of the injector nozzles into the gallery. Filtered oil under pressure is fed in to the
cylinder head is completed, nozzle protrusion of fuel injection pump during engine operation.
2.3/1.8 mm. is to be ensured. The cross sectional Excess oil above the center line of the pump
view of the engine showing the nozzle tip camshaft is allowed to drain back in to the oil
protrusion is show in fig.7. sump from the drive side of the pump camshaft.
With this arrangement, no periodic maintenance
is required for the fuel injection pump. In view of
NOTE : In the earlier engines, the copper washers the above system, the air breather tube, oil level
were graded as ‘A’ / ‘B’ and indicated in the screw plug, and the oil overflow banjo have been
washer by either a single slot or a double slot eliminated.
in the outer edge. In the present engines, a c. Removal
single standardized washer is used instead
1. Remove the fuel pipe to the injection pump
of two grades of washers. While servicing
and the return pipe from the injection pump
the engines of the earlier category, the
to filter.
graded washers can be replaced using the
2. Remove the injection pipes from the injectors
standardized washer.
and pump.

NOTE : Disconnecting the pipes at the injection pump a steady stream of fuel issues through the swan
and bending the out of the way will cause neck tube. Rotate the fuel injection pump body
faulty reassembly. They must be completely slightly about it’s camshaft axis.
removed. At a particular position, the stream of fuel will start
3. Disconnect the governor control rod and fuel dripping and finally stop. Tighten the three nuts
shut-off rod at the injection pump. and secure the fuel injection pump at this position.
4. Remove the injection pump gear cover. Remove the swan neck tube and install the
5. Remove the three cap screws securing the delivery valve and the high pressure pipe.
injection pump gear to the hub. f. Fuel Injection Equipment
6. Remove the three nuts securing the injection Normal care and cleanliness are required in
pump to the crankcase front plate and handling fuel and fuel injection equipment-and
withdraw the pump. (1-9). some additional points are as follows
78 NOTE : Kindly service your Fuel Injection System IMPORTANT FACTORS ON PREVENTIVE
from Authorised Dealer before installation. MAINTENANCE :
(i) Daily drain any water or sludge accumulation
d. Installation from the filters through the drain plug provided
1. Reverse the removal procedure ensuring that in the filter bowl.
the key in the gear is in engagement with the (ii) Do not run the vehicle or tractor with low fuel
keyway in the pump flange and that the level in the tank to prevent airation in the fuel
scribed mark on the pump mounting flange supply to the pump. It is very important to
is mid-way between the marks on the prevent the pump from running dry as the
crankcase front plate. lubrication to the pump barrels plungers is
2. Bleed the fuel system as per chapter III para e. through diesel oil only.
NOTE : Calibration chart of Fuel injection Pump
different models are given for your information
only.
e. Adjustments :
After installing the fuel injection pump, spill cut-
off operation has to be done in order to ensure
proper injection timing. For carrying out the spill
cut-off operation, the following equipments are
necessary.
(i) External Fuel Pumping Unit
(ii) Swan Neck tube
Set the No. 1 piston at the T.D.C on the
compression stroke by rotating the flywheel until
the No. 4 inlet valve is just beginning to open and
the No. 4 inlet valve is just beginning to close.
Rotate the flywheel a little, in the opposite
direction, so that the acid etched mark on the rim
of the crankshaft pulley coincides with the T.D.C
marker fixed on the cylinder block. Remove the
high pressure pipe connecting the No.1 injection
nozzle to the No.1 fuel pump unit. Remove the
delivery valve from the No.1 pumping unit and fit
the swan neck tube. Connect the external fuel
pumping unit to the fuel overflow port in the fuel
injection pump. Loosen the four bolts securing the
fuel injection pump so that the fuel injection pump
body can be rotated about the pump camshaft
axis. Prime the external fuel pumping unit so that

Air Cleaner & Fuel System - Rotary Fuel Injection Pump
Chapter-3 Rotary Fuel Injection Pump

Pump fitment / removal procedure
79
Filter element fitment and maintenance
Air Venting (Bleeding)
Low and high idle speed setting
Fault finding

ROTARY FUEL INJECTION PUMP

PUMP TO ENGINE FITMENT PROCEDURE
GENERAL DESCRIPTION:
1. The pump is supplied, with drive shaft timed and
locked at Start of Injection (SOI) condition
NOTE: 5A
• At the above condition, the Spacer (1A) provided
below Lockshaft screw will be moving freely.
• The position of the Lockshaft screw is as shown
in figure 2 & 3
80 Fig. 6
6. Hold the pump and hand tight the three washer
face bolts with spring washers (6A)
7. Fit the pump gear on the drive shaft and ensure
pump key in position with gear keyway (7A)
1A
Fig. 1 6A
Fig. 7
8. Rotate the pump in advance direction (ie) towards

Fig. 2 Fig. 3 the engine, till the pump gear fully positions with
2 The engine is set to 17°BTDC compression stroke pump drive shaft and also with Idler gear as
on number 1 cylinder shown (Fig – 9 & 10)
3. Ensure ‘O’ ring (3A) properly seated on the pump
flange
4. Position the pump on the spigot of engine front
plate as shown in figure 5
7A
3A
Fig. 4 Fig. 5
5. Rotate the pump to completely retarded timing

position (ie.) away from the engine (5A)
Fig. 8

9. Hand tighten the nut (9B) with spring washer (9A)

to pump drive shaft
10. Tighten the three pump mounting screws (6A-fig.7)
to the recommended torque of 30 NM
81
Fig. 9 Fig. 10 Fig. 13
11. On the pump, unlock the lockshaft timing screw NOTE:

and position to “run condition” • At the above condition, the Spacer below the
Lockshaft screw will be moving freely.
in fig. 3
2. Loosen the pump drive shaft nut and remove the
nut and spring washer carefully (Ref fig. 13, 11
& 12)
9A 9B
Fig. 11 Fig. 12
NOTE:
• Tighten the lockshaft timing screw to the
recommended value of 1 kgf-m torque.
• At the above condition, the movement of Spacer
(1A-fig.1) provided below Lockshaft screw will be
arrested.
1B
in fig. 3
12. Tighten the nut on the pump drive shaft to
1A
recommended torque of 70 NM as shown in fig.
13
Fig. 14
13. Rotate the crankshaft and ensure free
rotation of crank-cam-pump gear drive 3. Using a puller, detach FIP gear from the pump
drive shaft.
PUMP REMOVAL PROCEDURE
4. Unscrew the three washer faced pump mounting
GENERAL DESCRIPTION:
bolts along with spring washers (Ref fig. 7).
1. Rotate the crankshaft in the normal direction of
5. Remove the pump and ensure ‘O’ ring on the
rotation and set the engine to 17 0 BTDC
pump flange is not misplaced during removing
compression stroke on No.1 cylinder
(Ref fig. 4)
At this position lock the drive shaft of pump using
6. Provide protection caps to pump and place it in
the spacer (1A) and the locking screw (1B).
a dirt free area (Ref fig. 15)
Tighten the locking screw to 1 kgf-m

Fig. 18
AIR VENTING (BLEEDING)

GENERAL PRECAUTION
82 1. Ensure sufficient fuel in the fuel tank.
2. Ensure no air leak in fuel suction line (check fuel
Fig. 15 line joints from fuel tank to filter assembly and
FILTER ELEMENT FITMENT & MAINTENANCE to pump inlet).
GENERAL DESCRIPTION 3. While venting do not remove air vent screw and
FIP return banjo bolt fully out
1. Improper maintenance of filtration system can
cause serious damage to the fuel injection Air Vent
equipment. Screw Priming Pump Knob
2. Change filter elements and drain water at regular

intervals.
3. Avoid costly repairs by maintaining filtration
system as recommended by vehicle manufacturer
Fig. 19
AIR VENTING PROCEDURE

Fig. 16 Fig. 17 1. Loosen the air vent screw on filter assembly and
FIP return banjo bolt (Fig.19).
Changing the filter element 2. Loosen priming pump knob (Fig.19) and actuate
1. Clean the filter assembly externally (Ref Fig 16). the pump until fuel comes out without air bubble
2. Unscrew centre bolt (No. 2) and remove and from vent screw on filter assembly.
discard the filter elements (No.5) which needs 3. Tighten the vent screw.
replacement. 4. Energise the Solenoid switch (switch ON the
3. Remove and discard all rubber ‘O’ rings (No.4) ignition).
and washers. 5. Actuate the priming pump until fuel comes out
4. Clean internally the filter head and bowl without air bubble from FIP return.
(Ref Fig. 17). 6. Tighten FIP return banjo bolt to torque specified
5. Replace genuine ‘296’ filter element (Ref Fig18) (Fig.20).
along with new rubber ‘O’ rings. 7. Loosen all the high pressure pipes at injector end
6. Vent air from the system through air vent screw ((Fig.21).
(No.1) before starting the Tractor 8. Crank the engine while depressing the accelerator
pedal fully, until fuel flows freely from high
pressure pipe ends.

Return Banjo Bolt

Low Idle Screw
High Idle Screw
83
Fig. 20 Fig. 22
9. Connect and tighten high pressure pipes. 5. Tighten the locknut after setting the speed.
10. Start the engine and check fuel system for leak 6. Recheck the high idle speed after tightening the
locknut
High Pr. Pipe at Injector End
Fig. 21
Fig. 23
LOW IDLE AND HIGH IDLE SPEED SETTING
GENERAL PRECAUTION
1. Ensure setting the speed, only on a warmed up
engine.
2. Slacken the throttle link before setting the speed
SETTING THE SPEED

• LOW IDLE SPEED SETTING :
1. Slacken the low idle screw locknut and turn the
low idle screw to set low idle speed as specified
(Fig. 22 & 23).
2. Tighten the locknut after setting the speed.
3. Recheck the low idle speed after tightening the
locknut
• HIGH IDLE SPEED SETTING :
4. Slacken the high idle screw locknut (Fig. 22 &
23) and press the accelerator pedal fully down to
set high idle speed as specified.

84

85

86

Air Cleaner & Fuel System - Fuel Injection Pump Calibration Chart
Chapter-4 Fuel Injection Pump Calibration Chart

Test Specification Charts
87

Test Specifications
MICO (Subject to alterations)
Bosch Group For Field Service only
Mahindra Super Turbo 595 DI Sarpanch (Calibration Chart)
REFERENCE NO. : SSE-TS-MML 3.19 (B) ADJUSTMENT OF PUMP AND GOVERNOR
Edition : 10.1999
GUIDE SLEEVE TRAVEL
Replaces (edition : -
Control lever position : Free
Test oil : 9 916 034 004
Speed - min-1 (rpm) : 800
Combination : F 002 A0Z 143-E A40 0806 00 Control rack travel
Injection Pump : PES 4A 95D 320RS 2969 in mm : 0.3 - 0.7
88 Governor : RSV 425... 1050 A1C 1000 R 1. MAXIMUM SPEED CONTROL (RATED SPEED)
Customer : Mahindra & Mahindra Ltd. (without supplementary idling spring)
Engine model : MDI - 3000TC Control lever position : 610 ± 40

Engine code : 59113 Speed - min-1 (rpm) : 1050
Control rack travel
Application : Tractor
in mm : 9.7
TEST BENCH REQUIREMENTS Speed - min-1 (rpm) : 1110 - 1120
Test oil inlet Control rack travel
temperature : 380 - 420 C in mm : 8.7
Overflow valve : 9 451 037 430 Speed - min-1 (rpm) : 1130 - 1160
Control rack travel
Inlet pressure in bar : 1.5 in mm : 4.0
Test injector : 0 681 343 009 Speed - min-1 (rpm) : 1350
Opening pressure Control track travel
in bar : 172 - 176 in mm : 0.3 - 1.4
High Pressure pipe : 6 x 1.8 x 385
(OD x ID x length) in mm 2. FULL LOAD DELIVERY
Speed - min-1 (rpm) : 1050
(A) CALIBRATION OF PUMP WITHOUT GOVERNOR Boost pressure in bar : -
ACTION
Control rack travel
Direction of rotation : Clockwise in mm : 9.7
-
Delivery quantity (x)
Prestroke in mm : 3.25 - 3.35 (3.20 - 3.40)
Control rack in cm3/ 500 strokes : 35.8 - 36.3 (34.6 - 37.8)
position in mm : 9 - 12 Maximum spread
Cam sequence : 1-3-4-2 in cm3 (Δ) : 1.8 (4.0)
Cam displacement : 900 ± 0.50 Speed - min-1 (rpm) : -
Tappet clearance Boost pressure in bar : -
in mm : Min 0.2 Control rack travel
in mm : -
BASIC SETTING -
Speed - min-1 (rpm) : 1050 in cm3 / 500 strokes : -
Control rack Maximum spread
travel in mm : 9.7 in cm3 (Δ) : -
-
Delivery quantity(x)
3
in cm / 100 strokes : 7.4 - 7.6 3. TORQUE CONTROL
Maximum spread Speed - min-1 (rpm) : Not applicable
in cm3 (Δ) : 0.4 (0.8) Control rack travel
in mm : -
-1
Speed - min (rpm) : -
Speed - min-1 (rpm) : 425 Control rack travel
Control rack travel in mm : -
in mm : 6.0 Speed - min-1 (rpm) : -
-
Delivery quantity (x) Control rack travel
3
in cm / 100 strokes : 0.4 - 0.8 (0.2 -1.1) in mm : -
Maximum spread
in cm3 (Δ) : 0.6 (0.9)

SSE-TS-MML 3.19
4. COURSE OF DELIVERY 7. GOVERNOR CUTTING IN SPEED

Speed - min-1 (rpm) : 750 Speed - min-1 (rpm) : 1110 - 1120
Boost pressure in bar : - Control rack travel
-
Delivery quantity (x) in mm : Less by 1 mm from full pad
in cm3 / 500 strokes : 32.5 - 33 (31.3 - 34.3) control rack travel
Maximum spread
in cm3 (Δ) : 2.5 (4.0) While over checking, if the cutting-in speed is above the
Speed - min-1 (rpm) : - reated speed and if,
Boost pressure in bar : - - the delivery values are within the overchecking
-
Delivery quantity (x) : - tolerance
in cm3 / 500 strokes - control rack remains at full load position even at
50 min-1 (rpm) less than the rated speed 89
Maximum spread
in cm3 (Δ) : - the cutting-in speed should be declared OK.
5. IDLING SPEED CONTROL (RATED SPEED) 8. DEGREE OF IRREGULARITY

Control lever position : 310 ±40 Speed - min-1 (rpm) : 1150 - 1180
Speed - min-1 (rpm) :
425 Control rack travel
in mm : 4.0
Control rack travel
in mm : 8.2 No of notches : -18
100
Control rack travel 9. STARTING TRAVEL
in mm : Minimum 19.0 Speed - min-1 (rpm) : 100
425 Control rack travel
Control rack travel in mm : 19.5 - 21.0
in mm : 5.8 - 6.2
Speed - min-1 (rpm) : 540 - 600 10. STARTING FUEL DELIVERY
Control rack travel Speed - min-1 (rpm) : -
in mm : 2.0 Control rack travel
in mm : -
6. MAXIMUM SPEED CONTROL (RATED SPEED) -
(without supplementary idling spring)
in cm3 / 500 strokes : -
Speed - min-1 (rpm) : -
Control rack travel
in mm : -
Speed - min-1 (rpm) : -
Control rack travel
in mm : -
OTHER INFORMATION :
Element : F 002 B10 528 Adaption capsule : 9 430 034 281
Delivery valve : 9 411 038 576
Flyweight assembly : 1 428 194 019 Nozzle :
Governor spring : 1 424 650 005 Opening pressure
in bar : 250 - 258
Note :
1. Sl. No. of the operations indicate the sequence of operations
2. Values given in brackets are overchecking values
3. x- : Average of the cylinders
E0999
Applicable only for BOSCH and MICO test benches

These Test specifications should not be copied or transmitted to a third party without our written permission. All rights reserved.

Test Specifications
(Subject to alterations)
For Field Service only
585 DI
90

SSE-TS-MML 2.5 d1
91
-1 -1
Speed - min (rpm) : 800 Speed - min (rpm) : 1360 - 1370
Boost pressure in bar : - Control rack travel in mm : Less by 1 mm from full load
Delivery quantity ( x ) : 22.3 - 23.8 (21.3 - 24.8) control rack travel
in cm³ /500 strokes
Maximum spread in cm³ (Δ ) : 2.0 (4.0) While over checking, if the cutting-in speed is above the
-1
Speed - min (rpm) : - rated speed and if,
Boost pressure in bar : - - the delivery values are within the overchecking tolerance
-1
Delivery quantity ( x ) : - - control rack remains at full load position even at 50 min
in cm³/500 strokes - (rpm) less than the rated speed
Maximum spread in cm³ (Δ ) : - the cutting-in speed should be declared OK.
5. IDLING SPEED CONTROL (RATED SPEED)
8. DEGREE OF IRREGULARITY
o o
Control lever position : 22 ± 4
-1
Speed - min (rpm) : 1420 - 1450
-1
Speed - min (rpm) : 375 Control rack travel in mm : 4.0
Control rack travel in mm : 5.9 No of notches : ~16 E0900
-1
(rpm)
Speed - min Applicable : 100
only for BOSCH and MICO test benches
Control rack travel
Thesein mm : Minimum
Test specifications 9. STARTING
19.0not be copied or transmitted
should to a TRAVEL
third party without our written permission. All rights reserved.
-1
Speed - min (rpm) : 375
-1
Control rack travel in mm : 5.7 - 6.1 Speed - min (rpm) : 100
-1
Speed - min (rpm) : 580 - 640 Control rack travel in mm : 14.0 - 14.5
Control rack travel in mm : 2.0
6. MAXIMUM SPEED CONTROL (RATED SPEED) 10. STARTING FUEL DELIVERY
(with supplementary idling spring)
-1 -1
Speed - min (rpm) : - Speed - min (rpm) : -
Control rack travel in mm : - Control rack travel in mm : -
-1
Speed - min (rpm) : - Delivery quantity ( x ) : -
Control rack travel in mm : - in cm³ /500 strokes
OTHER INFORMATION :
Test Specifications
575 DI
REFERENCE NO : SSE-TS-MML 2.52 m (B) ADJUSTMENT OF PUMP AND GOVERNOR
Edition : 03.2002
Replaces (edition) : 08.2001 GUIDE SLEEVE TRAVEL
Test oil : 9 916 034 004 Control lever position : Free
-1
Combination No. : F 002 A0Z 204-E 040 1196 00 Speed - min (rpm) : 800
Injection pump : PES 4A 85D 320 RS 2997
92 1. MAXIMUM SPEED CONTROL (RATED SPEED)
Governor : RSV 350...1150 A1C 1236 R (without supplementary idling spring)
o o
Customer : Mahindra & Mahindra Ltd.
-1
Engine model : MDI 2500 Speed - min (rpm) : 1150
Engine code : 59075 Control rack travel in mm : 7.5
Application : Tractor (575 DI)
-1
TEST BENCH REQUIREMENTS Speed - min (rpm) : 1215 - 1225
o o
Test oil inlet temperature : 38 - 42 C
-1
Overflow valve : F 002 A10 627(9 451 037 430) Speed - min (rpm) : 1215 - 1245
Inlet pressure in bar : 1.5 Control rack travel in mm : 4.0
Test injector : 0 681 343 009
-1
Opening pressure in bar : 172 - 176 Speed - min (rpm) : 1400
High pressure pipe : 6 x 2 x 600 Control rack travel in mm : 0.3 - 1.4
(OD x ID x length) in mm
2. FULL LOAD DELIVERY
-1
(A) CALIBRATION OF PUMP WITHOUT GOVERNOR ACTION Speed - min (rpm) : 1150
Boost pressure in bar : -
Direction of rotation : Clockwise Control rack travel in mm : 7.5
Prestroke in mm : 3.20 - 3.30 ( 3.15 - 3.35) Delivery quantity ( x ) : 21.3 - 21.8 (20.3 - 22.8)
Control rack position in mm : 9 - 12 in cm³ /500 strokes
Cam sequence : 1-3-4-2 Maximum spread in cm³ (Δ ) : 1.5 (3.5)
o o -1
Cam displacement : 90 ± 0.5 Speed - min (rpm) : -
Tappet clearance in mm : Min 0.2 Boost pressure in bar : -
BASIC SETTING Delivery quantity ( x ) : -
-1
Speed - min (rpm) : 1150 Maximum spread in cm³ (Δ ) : -
Delivery quantity ( x ) : 4.2 - 4.4 3. TORQUE CONTROL
-1
Maximum spread in cm³ (Δ ) : 0.3 (0.7) Speed - min (rpm) : 600
-1
-1
Speed - min (rpm) : 350 Control rack travel in mm : 0.3 - 0.5
-1
Control rack travel in mm : 6.1 Speed - min (rpm) : 850
Delivery quantity ( x ) : 0.8 - 1.2 (0.6 - 1.4) Control rack travel in mm : 0.1 - 0.3
-1
in cm³ /100 strokes Speed - min (rpm) : 1150
Maximum spread in cm³ (Δ ) : 0.5 (0.7) Control rack travel in mm : 0

SSE-TS-MML 2.52 m
-1 -1
-1
Speed - min (rpm) : 750 rated speed and if,
-1
Delivery quantity ( x ) : 21.3 - 22.8 (20.3 - 23.8) - control rack remains at full load position even at 50 min
in cm³/500 strokes (rpm) less than the rated speed
93
Maximum spread in cm³ (Δ ) : 2.0 (4.0) the cutting-in speed should be declared OK.
o o
-1
Speed - min (rpm) : 1235 - 1265
-1
Control rack travel in mm : 6.1 No of notches : 12
-1
Control rack travel in mm : Minimum 19.0 9. STARTING TRAVEL
-1
-1
-1
-1 -1
-1
OTHER INFORMATION :
Element : 9 411 038 468 Adaption capsule : 1 420 506 716 (716)
Flyweight assembly : 1 428 194 019 Nozzle : 9 430 034 281
Governor spring : 1 424 650 005 Opening pressure in bar : 200 - 208
Note:
1 .Sl. No. of the operations indicate the sequence of operations. 3. X : Average of the cylinders
2 Values given in brackets are overchecking values
190202


Test Specifications
475 DI
REFERENCE NO : SSE-TS-MML 2.39 a (B) ADJUSTMENT OF PUMP AND GOVERNOR
Edition : 10.2000
Replaces (edition) : - GUIDE SLEEVE TRAVEL
-1
o o
-1
Engine model : MDI 2385A Speed - min (rpm) : 1150
-1
o o
-1
Overflow valve : 9 451 037 430 Speed - min (rpm) : 1210 - 1240
-1
-1
Cam sequence : 1-3-4-2 Maximum spread in cm³ (Δ ) : 1.5 (3.5)
o o -1
-1
-1
-1
-1
Speed - min (rpm) : 350 Control rack travel in mm : 0.6 - 0.9
-1
Control rack travel in mm : 6.3 Speed - min (rpm) : 875
Delivery quantity ( x ) : 0.7 - 1.1 (0.5 - 1.3) Control rack travel in mm : 0.3 - 0.5
-1

SSE-TS-MML 2.39 a
-1 -1
-1
-1
95
o o
-1
Speed - min (rpm) : 1230 - 1260
-1
Control rack travel in mm : 6.3 No of notches : ~ 12
-1
-1
-1
-1
-1 -1
-1
OTHER INFORMATION :
Element : 9 411 038 468 Adaption capsule ("C" Excn.) : 1 420 506 716 (716)
Note:
E0900


Test Specifications
275DI TU
REFERENCE NO : SSE-TS-MML 1.9 c (B) ADJUSTMENT OF PUMP AND GOVERNOR
Edition : 04.2000
-1
Combination No. : F002 A0Z 179-E 040 1139 00 Speed - min (rpm) : 800
1. MAXIMUM SPEED CONTROL (RATED SPEED)
96
o o
-1
Engine model : MDI 1895 B Speed - min (rpm) : 1300
Application : Tractor (B 275 DI)
-1
o o
-1
-1
-1
Cam sequence : 1-3-2 Maximum spread in cm³ (Δ ) : 1.5 (3.5)
o o -1
-1
-1
Maximum spread in cm³ (Δ ) : 0.3 (0.7) Speed - min (rpm) : -
-1 -1
Speed - min (rpm) : 425 Speed - min (rpm) : -
Control rack travel in mm : 6.0 Control rack travel in mm : -
Delivery quantity ( x ) : 0.5 - 0.9 (0.3 - 1.1)
-1
in cm³ /100 strokes Speed - min (rpm) : -
Maximum spread in cm³ (Δ ) : 0.5 (0.7) Control rack travel in mm : -

SSE-TS-MML 1.9 c
-1 -1
-1
-1
in cm³/500 strokes - (rpm) less than the rated speed 97
o o
-1
Speed - min (rpm) : 1425 - 1455
-1
Control rack travel in mm : 6.0 No of notches : ~10
-1
-1
-1
-1
-1 -1
-1
OTHER INFORMATION : Adaption capsule : -

Element : 9 411 038 468
Note:
E0100


Test Specifications
275 DI Long Stroke
REFERENCE NO : SSE-TS-MML 2.05 (B) ADJUSTMENT OF PUMP AND GOVERNOR
Edition : 07.2001
-1
Injection pump : PES 3 A 85 D 320 RS 2924
o o
-1
Application : Tractor (275 DI TU)
-1
o o
-1
Overflow valve : 9 451 037 430(F 002 A10 627) Speed - min (rpm) : 1285 - 1315
-1
-1
o o -1
-1
-1
-1 -1
Speed - min (rpm) : 425 Speed - min (rpm) : 800
Control rack travel in mm : 6.2 - 6.3 Control rack travel in mm : 0.1 - 0.3
-1

SSE-TS-MML 2.05
-1 -1
-1
-1
99
o o
-1
Speed - min (rpm) : 1320 - 1350
-1
Control rack travel in mm : 6.2 - 6.3 No of notches : ~12
-1
-1
-1
-1
-1 -1
-1
OTHER INFORMATION :
Note:
240501


Test Specifications
275 DI
REFERENCE NO : SSE-TS-MML 1.89 d (B) ADJUSTMENT OF PUMP AND GOVERNOR
Edition : 10.2000
-1
Injection pump : PES 3A 85D 320RS 2998
Governor : RS V350...1150 A1C 1237 R (without supplementary idling spring)
o o
-1
-1
o o
-1
-1
-1
o o -1
-1
-1
-1 -1
-1

SSE-TS-MML 1.89 d
-1 -1
Delivery quantity ( x ) : 19.3 - 20.8(18.3 - 21.8) control rack travel
-1
-1
101
o o
-1
Speed - min (rpm) : 1230 - 1260
-1
-1
-1
-1
-1
-1 -1
-1
OTHER INFORMATION :
Element : 9 411 038 468 Adaption capsule : -
Note:
E0900


Test Specifications
265 & 365 DI
REFERENCE NO : SSE-TS-MML 1.8 a (B) ADJUSTMENT OF PUMP AND GOVERNOR
Edition : 10.2000
-1
Combination No. : F002 A0Z 206-E 040 1198 00 Speed - min (rpm) : 800
o o
-1
-1
o o
-1
-1
-1
o o -1
-1
-1
-1 -1
-1

SSE-TS-MML 1.8 a
-1 -1
-1
-1
103
o o
-1
Speed - min (rpm) : 1230 - 1260
-1
-1
-1
-1
-1
-1 -1
-1
OTHER INFORMATION :
Element : 9 411 038 468 Adaption capsule : -
Note:
E0700


Test Specifications
255 DI Long Stroke
REFERENCE NO : SSE-TS-MML 1.26 b (B) ADJUSTMENT OF PUMP AND GOVERNOR
Edition : 06.2001
-1
Injection pump : PES 2 A 85 D 320 RS 2925
o o
-1
Application : Tractor –255 DI
-1
o o
-1
-1
-1
Cam sequence : 1-2 Maximum spread in cm³ (Δ ) : 1.5 (3.5)
o o -1
-1
-1
-1 -1
Speed - min (rpm) : 425 Speed - min (rpm) : 800
Control rack travel in mm : 5.7 Control rack travel in mm : 0.1 - 0.4
-1

SSE-TS-MML 1.26 b
-1 -1
-1
-1
105
o o
-1
Speed - min (rpm) : 1305 - 1335
-1
-1
-1
-1
-1
-1 -1
-1
OTHER INFORMATION :
Flyweight assembly : 1 428 194 021 Nozzle : F 002 C40 509
Note:
210201


Air Cleaner & Fuel System
Notes :
106

GROUP - 4
Cooling System
Specifications
Description
Radiator
Fan & Fan Belt
Water Pump Assembly
Hoses
Trouble Shooting

Cooling System
1. SPECIFICATIONS
Capacity - Litre 5.5 - 7.95 Litres
Pump - type Centrifugel
- direction of rotation viewed from front Clockwise
Fan Belt - type Single V
- slack between pulleys 9.5mm - 12.7mm
Thermostat - operating temperature 740 - 840
Operating Pressure 0.8 - 0.9 Kg/sq cm
108

Cooling System
2. RADIATOR b) To prevent the water vaporization of the Coolant.

1. The Radiator are of two types (A) Copper Radiator c) The Cap releases excess pressure via the
and (B) Alluminium Radiator. overflow tube in the filler neck when the pressure
A) Copper Radiator : The Radiator is the flat tube rises beyond the specified pressure. The pressure
type with the core and water tanks combined in inside the Radiator is always maintained within
one Integral Unit. It is enclosed within a Grille and close limits of the Valve specified on the Cap.
fan housing which are removable for cleaning. d) The Cap also has a vacuum release valve which
Radiator water filler cap is a pressure cap and is relieves vacuum created when the engine is cools
fitted on the filler neck. The pressure cap has the and coolant temperature drop. The Valve opens
following functions and equalises the System Pressure with
atmosphere via, overflow tube of the filler neck
a) Pressures the System thus raising the boiling
(see fig 1B).
point of the Coolant.
109
1. Radiator 5. Fan guard L.H. 9. Clip hose 13. Radiator drain cock
2. Cap 6. Fan guard R.H. 10. Pad Radiator
3. Radiator base 7. Outlet hose 11. Spring
4. Fan cowl 8. Inlet hose 12. Bolt

Cooling System
j. Remove the two nuts from the bolts securing the

radiator to the front axle support and lift the
radiator and rubber pads clear.
k. Remove the fan housing from the radiator.
2. Cleaning, Inspection and Repair
a. Flush out the core with water and air under
pressure. If the interior is greasy, use steam
cleaning equipment.
Fig.1B - Operation of the vacuum release valve b. Clean the outside of the core with water under
1. Cap top 2. Overflow tube pressure. Flush out between the fins and tubes
3. Rubber pad 4. Filler neck
thoroughly.
c. Inspect the top and bottom tanks for cracks.
NOTE : 1. If the Radiator Cap is defective i.e.Rubber Inspect the fins and tubes for damage. If
Seals and Valve Springs broken, replace it. soldering does not effect a satisfactory repair the
2. Do not remove rubber seal of radiator cap. radiator must be replaced.
NOTE : For the Engine to run efficiently, the radiator
110 1. Removal core should be clean and free from grease,
a. Drain the coolant. ruste and scales to allow free passage of the
b. Remove the vertical exhaust silencer, precleaner Cooling Medium and maximum heat transfer.
and raise the hood. Cleaning out Dirt and Sludge - For Copper
c. Disconnect the battery earth cable before Radiator.
disconnecting any electrical system. Drain cooling system as directed above. Fill the
d. Unclip the main cable harness from the bottom cooling system with a solution of 1.36 kgs. of
of the radiator. ordinary baking soda to 10.19 litres of water. Do
e. Disconnect the head lamp and horn cables if not replace the radiator cap. Operate the engine
fitted. until the water is hot. Drain, flush with clean water
and refill with anti-freeze solution.
f. Remove the bolts from the bottom of the radiator
grill and remove the hood and radiator grill. The system should be kept filled with clean water
with a rust inhibitor or anti-freeze solution.
g. Open the Radiator and crankcase drain taps and
allow the system to drain. d. Method of De-Scaling and Flushing :
h. Disconnect the radiator brace at the radiator end A Chemical Scale Remover is available in the
(5-4). Market like Brand Name “Core Guard” or some
other names.
i. Loosen the clamps (2-4) on the radiator hoses
(3,4-4) and Work the hoses free of the inlet and a) Remove the Radiator from the Tractor as
outlet pipes of the radiator. explained in para b2.
b) Block Inlet and Outlet Pipes with suitable
adapters. Connected an air pressure hose to the
inlet Adapter.
c) Close the drain cock and fill up the radiator with
a Scale Remover Chemical.
d) Close the Radiator with Pressure Cap immediately
and pressurise the Radiator to 0.35 kg/cm2
e) Open partially the drain cock allowing the chemical
to drain slowly in the plastic bucket.
f) Once the Radiator is fully drained close the drain
cook and repeat the procedure twice more. At the
end of the 3rd round the radiator would have been
thoroughly cleaned. Finally drain the system of
chemical. Flush the Radiator with clean water.
Fig. 5

Cooling System
Flushing the Radiator : d) Ensure that filler cap of Recovery Bottle is

g) Thoroughly flush inside of the Radiator using good fitted properly Ensure that all joints are leak
clean water. proof.
The outside of the Core should be flushed well
to remove the dust particles and impediments DONT’S
stuck to the fins and tubes. a) Fill coolant above Max level marking of
The Radiator should then be blown dry with Recovery bottle
compressed air. APPROX COOLING SYSTEM CAPACITY
The Radiator is now ready for installation. (INCLUDING RECOVERY BOTTLE )
3. Installation 4 DI models- 7 Ltrs
1. Assemble the fan housing to the radiator. 3 DI models-5.5 Ltrs
2. Position the radiator mounting pads on the front 2 DI models-4 Ltrs
axle support over the radiator bolt holes. Lift the Coolant capacity between minimum & maximum mark
radiator into position and fit the nuts. in Recovery Bottle –0.5 Ltr
3. Reassemble the inlet and outlet hoses end tighten In Recovery Bottle-the Min marking is calibrated at
the clamps securely. 0.5 Ltr & Max mark at 1 Ltr. 111
4. Reconnect the radiator brace.
5. Place the hood and radiator grille in position and Clip Spring
secure with the two pivot bolts.
Bracket -
6. Connect the head lamp and horn cables. Top
7. Replace the main harness into the clip at the Bolt
bottom of the radiator and secure the clip. Spacer
8. Connect the battery earth lead.
Recovery
9. Fill the radiator with clean coolant solution. Bottle
Max Bolt
10. Lower the hood into position and fit the exhaust
silencer and precleaner. Vent
Min
Tube
B) Alluminum Radiator :
To reduce the frequency of coolant top-up the
alluminium radiator is provided with recovery bottle.
Bracket -
1) Recovery Bottle (fig. 1c) Side
a) Reduced frequency of coolant Top up Bolt
In normal running conditions water vapour &
overflow water from radiator gets collected
in Recovery Bottle, which is then siphoned
back to radiator when engine gets cooler
b) Long life of engine & radiator Due to reduced
frequency of top up , the chances of adding
unwanted salts(dissolved in water) are less.
This in turn reduces corrosion, Scaling &
deposition inside radiator & engine Fig. 1c
DO,S
a) Daily check water level in recovery bottle
b) Top up Recovery bottle when the level
reaches at minimum level. approximately
0.5 Litre clean water & 50 ml Zero-R should
be added to reach up to maximum mark
c) Ensure that Radiator pressure cap is fitted
properly

Cooling System
2) Procedure to service alluminium radiator : 3) Dip the radiator completely in a clean water
The procedure covers the following aspects of the tank.
servicing 4) Tilt the radiator, shake it vigorously & observe
a) Leakage spot detection carefully for one minute. Air bubbles will be
b) Sealing Techniques & the tools required observed at the point of leakage from radiator.
c) Confirmation of proper sealing
SEALING THE LEAKAGE SPOT (fig. 1d and 1e)
TOOL KIT : a) At Plastic Tank
Following tools are required • Release the clinch projections of header plate
using screwdriver .After making all clinching
1) Screw driver
projections up, take out the tank from its seat
2) Monkey plier
in header plate using rubber or plastic
3) Quick setting Araldite hammer.
4) Brush • Take out the rubber sealing ring
• Clean the area of the header plate where the
112 PROCEDURE FOR SERVICING tank sits, thoroughly.
1) Drain the coolant completely • Insert new tank packing in the place without
2) Remove the mounting fasteners, attachments twisting.
like shroud, hoses etc. • Use new tank (top or bottom) if required
3) Remove the radiator from vehicle • If the source of leakage is at the base of the
tank, i.e. area between header plate & tank,
DETECTION OF LEAKAGE SPOT it means tank sealing ring is defective hence
the same can be replaced
1) Connect the inlet of the radiator to air supply
at the gauge pressure of 1.5 bar. • Adopt the following Process to clinch the tank
to radiatore core
2) Seal all the outlet points
• Locate the tank on core by pressing few
clinches at the corners & few at the center
• Softly hammer all the clinches with plastic
mallet
• Now press one by one all clinches with
monkey plier
• Carry out the leakage test as per procedure
mentioned above before refitting the radiator
on tractor
b) At Radiator Core.
Fig. 1d • Procedure for sealing leaks inside radiator
core.
• Wash the radiator core with clean water &
brush to remove dirt, dust etc.
• If any greasy spot is there , apply thinner
with cotton swab & take off the grease.
• Dry the core using a dryer/ compressed air
• Mix adequate quantity of quick setting
Araldite resin & hardener in the ratio of 1:1
and stir it thoroughly.
• Apply the mixture immediately at the leakage
Fig. 1e spot allow the mixture to set, as Araldite is
inflammable, do not dry it by heating.

Cooling System
• Subject the assembled radiator to leakage replaced as they are difficult to balance.
test as explained in leakage detection The Fan Belt needs periodical inspection.
procedure. After the sealing work is over, The bell tension is correct when it can be
assemble the radiator . depressed 9.5mm to 12.7mm by thumb pressure
• Connect the inlet & outlet hoses & clamp midway between the pulleys (fig. 2).
them to the radiator. 1.a. Remove vertical exhaust, precleaner and raise the
• Fit the fan shroud. hood.
• Fill the radiator with proper quantity of Zero- b. Remove the radiator to cylinder head cover brace.
R & clean (distilled) water c. To remove the fan belt, loosen the hold screw in
Note: the flange (1-3) on the fan pulley and unscrew the
Sealing Ring is to be replaced every time the tank is flange (2-3) as far as possible with the help of
opened for servicing special service tool MST-H1-EN-2 (fig. 2a) Start
the belt over the outer flange of the lower pulley
If any of the clinching projections is broken during the
(CRANKSHAFT) and pry it out with a light bar or
clinching or releasing process, discontinue the servicing
rod. Slowly crank the engine at the same time
& replace the entire radiator by new one.
and the belt will work off the pulley. Withdraw the
Do not use the water tank that is used for copper belt between the pulley and the bolster. The belt 113
radiators. can now be worked over the fan blades.
Replace the pressure cap if found defective
Ensure that fins are not damaged during the process.
Ensure thorough cleaning of radiator core for proper
setting of Araldite or else it will come off.
PRECAUTIONS
• Never open the pressure cap when the
radiator is hot.
• Do not use acid / caustic soda solution for Fig. 2a
cleaning the tubes & tanks.
d. Remove the six round headed cap-screws and
• Do not use any sharp object for cleaning
their washers and nuts which secure the fan
clogged tubes.
housing to the radiator and move the housing back
4. FAN AND FAN BELT : towards the pulley as far as possible.
Little need be said about servicing the Fan but
it should be checked occasionally for loose or
bent blades. Either condition will usually make its
presence felt by Fan vibration.
Damaged/unbalanced Fan Blades are to be
Fig. 2 Fig. 3

Cooling System
3 5 2 fitted to front end of it. The Spindle Shaft is

provided with Seal. The Water Pump is fastened
to the front end of the Crankcase. The Water
Pump and Fan Assembly is Belt driven by the
Engine Crankshaft Pulley.
1. Removal
a. Drain the coolant.
b. Remove the vertical exhaust silencer, precleaner
and raise hood.
c. Remove the fan (Refer to para.4 (c) REMOVAL).
d. Unscrew the alternator mounting bolt & nut, loose
the nut, bolt (7-4) of alternator adjustment brace.
Slide off the alternator belt.
e. Loosen the inlet hose clamp which clamps the
hose to the radiator inlet tube and work the hose
114 free from the tube.
f. Disconnect the battery earth lead.
g. Loosen the outlet hose clamp which clamps the
Fig. 4 hose to the water pump and work the hose free
from the pump. Slacken the two hoseclips (1-7)
e. Remove the four capscrews which secure the fan then remove the thermostat by pass hose (2-7).
to the pulley hub. To remove these capscrews h. Lift the fan housing clear of the tractor.
work from the right hand side of the machine and i. Remove the nut and setscrew which secures the
ensure that each capscrew is rotated up to the adjustable pulley flange to the pulley hub and
12 o’clock position as it is being removed. unscrew the flange from the hub. Slide off the
2. Installation drive belt.
a. Insert the fan into position from the right hand j. Unscrew the four nuts (3-7) from the water pump
side of the machine. mounting studs.
b. Attach the fan to the pulley hub with one k. Withdraw the water pump as far as possible along
capscrew loosely screwed down. Turn the fan and the mounting studs and towards the radiator.
hub until the next hole is at the 12 o’ clock 2. Dismantling
position and insert the second capscrew and only
half tighten down. Repeat this procedure for the
following capscrew, then tighten the four
capscrews down very carefully and securely.
c. Check and ensure that the fan blades do not foul
the fan housing.
d. When replacing the belt, reverse the procedure
outlined under “REMOVING THE FANBELT”
except that the belt can be started on the lower
pulley (CRANKSHAFT) by hand. By slowly
cranking engine, the belt will find the correct
position.
5. WATER PUMP
The water pump circulates the Coolant. The water
pump is a centrifugal type with self lubricated
sealed two row ball bearings. The Impeller is an
interference fit to the rear end of the spindle
Fig. 7
bearing shaft and pulley hub is an interference

Cooling System
a. Bolt a plate similar to that shown in Fig. 8 to the d. Press the spindle, bearing shaft (2-9) and impeller
four fan mounting holes and secure the plate in (2-10) out of the water pump body (3-9).
a vice. e. i) Support the seal at its inner cage.
b. Using a suitable bolt in the centre hole of the ii) Apply load on the bearing shaft, and push it
plate drive the shaft out of the pulley hub. The out of the seal Assy.
impeller and pump body will come off as one unit. NOTE : It is recommended to replace the entire water
pump unit rather than repairing it.
3. Inspection and Repair

a. Check all parts for wear or excessive rust or scale.
b. Check the fit of the spindle bearing shaft in the
impellor bore and the pulley hub bore to
specifications.
c. Check the fit of the spindle bearing shaft in the
water pump body to specifications.
d. Check the water flinger and seal for wear or
damage.
115
NOTE : Bearing : It should not have excessive play
& should be free from noise while rotating
the bearing shaft.
Hub : The hub & the bearing shaft should
have interference fit.
Pulley : Ensure that the pulley and hub
Fig. 8 threads are not damaged.
c. Remove the bearing retaining screw or clip Seal : The Seal must be replaced whenever
(1-9) and lockwasher. Remove the clip by pulling the water pump is Dismantled.
it out with the help of a plier. Ensure that the clip
does not break inside the Pump Body. 4. Assembly
a. Install the water flinger and seal on the spindle
bearing ensuring that the carbon thrust ring of the
seal is away from the bearing.
b. Press on the impeller ensuring that the face of
the impeller hub is flush with the end of the
spindle.
6. WATER PUMP ASSEMBLY

a. Dismantling:
Fig. 9 Remove the pulley hub (12-10a) from the spindle
(11-10a). Remove bearing retaining clip (10-10a).
Press the spindle bearing shaft and impeller out
of the housing towards the impeller housing. Press
the spindle bearing shaft out of the impeller (2-
10a) and remove the seal assembly (5-10a) and
the water slinger (6-10a) In the case of a water
pump with ceramic insert remove the ceramic
insert (4-10a) and the rubber boot
(3-10a).
b. Inspection & Repair:

Examine all the parts for excessive rust or scale.
Check the fit of the spindle bearing shaft to the
Fig. 10
impeller bore. The interference fit should never be

Cooling System
less than 0.025 mm. Check the fit of the spindle

bearing shaft to the pulley hub bore.
The interference fit should never be less than
0.025 mm. Check the fit of the spindle bearing
shaft to the water pump housing. The fit can vary
from 0.0025 mm loose to 0.025 mm tight. Examine
Fig. 10a - Water Pump Assembly the water slinger and ensure that it has not
1. Gasket 2. Impeller cracked or split. Check the seal for signs of
3. Rubber Boot 4. Ceramic Insert excessive wear or loss of spring action. Examine
5. Seal 6. Slinger the ceramic insert for cracks or pitting. Check the
7. Body 8. Lockwasher
rubber boot for twisting or breakage.
9. Hex.hd.nut 10. Clip
11. Spindle 12. Pulley
c. Assembly:
Install the seal and slinger on the spindle bearing
ensuring that the carbon thrust ring of the seal
is away from the bearing. In the case of a water
pump with a ceramic insert press the rubber boot
116 and the ceramic insert in to the impeller. Press
the impeller over the spindle making sure that the
face of the impeller hub is flush with the end of
Fig. 1a the spindle. Press the spindle bearing shaft into
the water pump aligning the groove in the bearing
with the bolt hole in the water pump body. Ensure
that the impellor is flush with the base of the
Clip
water pump body (Fig. 11). Install the bearing
Fig. 2a retaining screw and lockwasher. Press the pulley
hub on the spindle. Ensure an overall length of
156.38 mm from the outer pulley hub face to the
outer impeller face.
d. Installation
(a) Reverse the removal procedure using a new
gasket and tighten the nuts to the correct
torque.
Fig. 3a
ASSEMBLY PROCEDURE OF WATER PUMP WITH
UNITIZED SEAL
Pump Body
a. Position the bearing assy. inside the waterpump
body as shown in fig-6a & apply load on the
bearing outer race. Push the bearing inside the
body till the clip groove on the bearing aligns with
Fig. 4a its slot in the water pump body.
b. Tap the clip inside the slot in water pump body,
& ensure that it is properly seated.
c. Support the bearing shaft as shown in fig-7a.
Position the pulley hub on top of the shaft as
shown fig. and push it on the shaft until the top
face of the hub gets aligned with the top surface
of the bearing shaft. Check for free rotation of the
pulley hub.
Fig. 5a

Cooling System
d. Support the bearing shaft as shown in fig-8a.

Position the unitised seal on the bearing shaft as
shown in figure. With the help of the special tool
(Pressing dolly) press down the seal Assy on the
shaft and inside the body till it seats properly in
its place. (as shown in Fig-9a)
Special tool for assembling unitised seal :
Dolley - Unitised seal assembly.
e. Support to the bearing shaft as shown in fig-9a.
Position the impeller on the bearing shaft as
shown in fig-9a. Press the impeller on the bearing
shaft until the impeller top surfaces aligns with Fig. 6a
the bearing shaft top face.
NOTE : The hub should rotate freely after assembly.
Clip (used for holding bearing) should be
properly seated.
117
4) THERMOSTAT :
The Blocker type Thermostat is located in
Thermostat Housing. The Thermostat controls the
Engine operating temperature.
When the Engine is cold the Thermostat is
closed, preventing circulation of Coolant until it
reaches operating temperature. The thermostat is
set to begin to open at 740 Centigrade and be
Fig. 7a
wide open at 820 Centigrade.
NOTE : When the Thermostat fails in the open
position, the Engine runs too cold. Thereby
the Cylinder Sleeves get glazed, leading to
excessive consumption of Lubricating Oil. A
Cold running Engine is damaged by
combustion gas. ‘blow by’, Crankcase
condensation resulting in sludge formation in
the Oil, High wear and corrosion of Engine
parts and rapid clogging of the positive
Crankcase ventilation system.
WARNING : Do not to remove the Thermostat
from Tractors for any reason whatsoever except to
Fig. 8a
replace a defective thermostat.
80.45mm
THIS
FACE TO
BE FLUSH
WITH BASE
OF WATER
PUMP BODY
140.49mm
Fig. 9a
Fig. 11

Cooling System
b. Removal (c) Installation

1. Drain the cooling system. 1. Insert the thermostat into its housing with the
2. Loosen the clamps on the radiator upper hose bellows end downwards and install new
and work the hose clear of the thermostat gasket.
housing. 2. Tighten the capscrews.
3. Remove the three capscrews (1-12) from the 3. Work the hose back on to the thermostat
thermostat housing (2-12) and withdraw the housing and tighten the hose clamps
thermostat. securely.
4. Fill the radiator with clean water.
7. HOSES :
Top and bottom hoses should be checked at least
twice a year for deterioration. The main thing to look
for are hardness or conversely, sponginess. In first
case, hardness leads to lack of flexibility and cracking;
118 the latter causing leakage and also allows the passage
of small particles of rubber into the Radiator, blocking
the cores. Sponginess leads to lining failure and
eventual rupture of the Hose.
When installing new hoses, particular attention should
be paid to the connections. If you want a first class
job, the steel pipe connections should be cleaned and
non hardening sealing compound used in conjunction
Fig. 12 with original/good quality Hose Clips always fitted with
the Screw Heads in the most convenient position for
2) INSPECTION adjustment with the Screw Driver. All new Hoses and
Suspend the thermostat and a thermometer in a their connection should be checked a couple of times
pan of water until the thermostat opens. It should subsequent to fitting. After the Engine has been in
begin to open at 74OC and fully open by 82OC. use, retighten all connections, as necessary.
8. TROUBLE SHOOTING
TROUBLE PROBABLE CAUSE REMEDY
1. Insufficient water 1. Acid water, inspect for leaks.
2. Faulty Thermostat 2. Test, it necessary, replace.
3. Dirty Water 3. Drain & clean system.
4. Defective Connections. 4. Replace swollen, worn or
loose hose connections.
DEFECTIVE 5. Radiator Defective 5. Repair. If necessary, replace.
COOLING 6. Fan Detective 6. Inspect Fan. If damaged, replace.
SYSTEM 7. Defective Radiator Cap. 7. Replace.
8. Defective Water Pump. 8. Inspect water pump impeller
& shaft. If necessary, replace.
9. Dirty, Scad Coolant passages. 9. Clean & flush passages.
10. Radiator Togged. 10. Flush out radiator.
11. Fan Roll Slippage. 11. Check the tension; replace,
it greasy or worn.

GROUP - 5
Clutch
Specifications
Description
Removal
Dismantling of Single Plate Coil Clutch
Cleaning, Inspection & Repair
Assembly
Installation
Adjustments, Dismantling, Cleaning, Inspection & Repair, Assembly
of Single Plate & Dual Plate Diapraghm Clutch
Removal, Dismantling, Assembly, Installation of Clutch Mechanism
Trouble Shooting

Clutch
1. SPECIFICATIONS
A. SINGLE PLATE CLUTCH

Make ...................................................................................................................................................... Valeo
Type of clutch ................................................................................................................. Single plate diaphragm
Drive plate dia (mm) ................................................................................................................................... 279.4
No. of thrust spring .............................................................................................................................................9
Release bearing type ........................................................................................................... Anti friction bearing
PEDAL SETTING
Pedal height from foot plate (mm) ................................................................................................................. 152
Pedal free travel (mm) .............................................................................................................................. 19 - 25
PEDAL SETTING
Pedal height to foot plate (mm) ..................................................................................................................... 177
Pedal free travel (mm) ............................................................................................................................ 12 to 19
120
B. DUAL CLUTCH
Make Dual Plate ................................................................................................................................... Rane Luk
Type of clutch ..........................................................................................................................Spring loaded dry
Dry ceramic pad
Main drive member (mm) ........................................................................................................................... 279.4
P.T.O. drive member (mm) ......................................................................................................................... 279.4
CLEARANCE
Release bearing to release finger (mm) ............................................................................................................. 4
Release lever height from flywheel (main drive) (mm) ................................................................................... 97
P.T.O. release lever height from flywheel (mm) .............................................................................................. 89
PEDAL SETTING
Pedal height to foot plate (mm) ..................................................................................................................... 165
Pedal freeplay (mm) ............................................................................................................................... 15 to 20
TORQUE Newton meter

Clutch housing mounting bolt ............................................................................................................... 135 - 150
Clutch release fork bolt ............................................................................................................................ 20 - 27
Clutch pedal release adjusting bracket .................................................................................................... 20 - 27
Clutch assy. mounting bolt ....................................................................................................................... 40 - 47

Clutch
TIPS ON CLUTCH
Diaphragm spring are designed to provide years of d. Use the clutch when performing normal upshifts
trouble free service. However, if the tractors are not and downshifts.
serviced and driven correctly will significantly reduce e. Make every effort to match the engine speed to
the clutch life. the transmission input shaft speed during shifting
Preventing clutch slippage gear to avoid inducing drive train shock loads.
Clutch wear life is depend on driver’s handling and f. Read just the release bearing position whenever
habits of driving. Therefore, to maximize life, abnormal the clutch pedal free play drops below
or excessive slippage must be avoided. If the clutch specification.
begins to slip, back of the throttle or change to lower DON’T :
gear to stop the slippage. If slipping continues more
a. Start the tractor with high engine rpm and long
the few seconds under high load condition, the clutch
clutch slippage time or the clutch will overheat.
will become hot and will fade. Excessive slippage or
overheating occur, stop the tractor off the road and b. Start the tractor with very short clutch slip time
allow the clutch to cool. If the clutch continues to slip that shock the driveline.
after cooling, downshift one or two gears until the c. Upshift or downshift before reaching the correct
slippage stops. Then drive to the nearest service engine rpm because this will shock load the
station to have a clutch adjusted or repaired as driveline.
needed. d. Rest your foot on the clutch pedal. This will start
The following are driver tips on how to improve clutch to disengage the clutch and could cause slippage.
121
performance and extend the useful life of the entire e. Coast down hill with the clutch disengaged and
driveline. the transmission in gear. Safe vehicle control will
DO : be lost and maximum clutch disc rpm operating
a. Gently engage the clutches while engine is at idle limits could be exceeded.
and start increasing the throttle only after the f. Use the clutch to stop the tractor vehicle or hold
clutch is fully engages. it on a hill. It is too fragile for this purpose.
b. Start the tractor in a lower gear enough to allow g. Slip the clutch to hold the tractor in place on a
a smooth and quick clutch engagement. hill. This will quickly overheat the clutch.
c. Minimise clutch engagement slip time to avoid
excessive heat generated.

Clutch - Single Plate Coil
2. DESCRIPTION
a. GENERAL
Two types of clutches are used on Mahindra
Tractors. They may be equipped with a 11” and
10” single plate clutch or, a dual plate clutch with
a 11”main driven member and a 9” or 11” P.T.O.
driven member. The single plate clutch is used
in tractors equipped with transmission drive P.T.O.
and the dual stage clutch is used in tractors
equipped with a continuous running P.T.O.
Fig. 2
122
Fig. 2a (supports for rail and jack kit)

Fig. 1
b. SINGLE PLATE CLUTCH IT IS OF TWO TYPES b) Mount the supports over jacks (rail and jack
1. Coil type clutch : kit MST-H1/2-MP-1) by inserting shaft of
The single plate clutch is a foot operated dry jacks in bushes given under support.
plate type. It consists of a driven plate assembly, c) Remove air precleaner and vertical exhaust.
cover assembly and a release bearing assembly. d) Remove the hood.
The driven plate assembly is clamped between
e) Remove the battery cover and disconnect the
the flywheel rear face and the cover assembly
battery leads.
which is bolted to the flywheel.
The cover assembly is composed of a pressed f) Disconnect the governor control rod and the
steel cover plate, a cast iron pressure plate (that battery tray and fuel shut-off rod at the
engages the driven plate), thrust springs which injection pump.
provide the champing force to the pressure plate, g) Turn off the fuel tap and remove the fuel pipe
three release levers, floating pins, eye bolts, from the tap to feed pump. Disconnect the
adjusting nuts, struts and anti-rattle springs. The fuel over flow pipe at the fuel tank.
release levers pivot on floating pins. They are
h) Disconnect the main cable harness at
retained in the cover by the eyebolts; the
multiple socket.
adjusting nuts are used to regulate release lever
height. The struts hold the pressure plate and i) Disconnect the power steering oil pipes and
other parts in alignment. clips to free pipes from clutch housing.
Disconnect the draglink at the steering drop
3. REMOVAL arm if mechanical steering is fitted.
a) To remove the clutch the engine must NOTE : Plug the opening immediately to prevent dirt
be separated from the clutch housing, from entering steering system, fuel system.
use special service tool supports MST-H2- j) Disconnect the oil pressure pipe from elbow
MP-2 (fig 2a) to seperate the engine from union on the right hand side of the
clutch housing. crankcase. Cover the openings.

k) Remove the heat indicator bulb from the

cylinder head.
l) Disconnect the hydraulic pipes from the
hydraulic pump and mask the ports.
m) Disconnect the RPM cum hour meter cable
drive.
n) Remove the two bolts of stay rod cap from
clutch housing.
o) Block the rear wheels and ensure that the
hand brake lever is locked in the “ON”
position (to ensure that the rear tires can not
move while separating the engine from the
transmission / clutch housings.)
Put a sling round the engine and front end.
Take care not to raise the engine too high as
this will cause distortion of the clutch shaft
when the engine is removed. Fig. 3
1. Lever Plate 8. Pin Cotter
p) Remove the clutch housing front dust cover.
2. Cover 9. Yoke
q) Place wooden blocks between front axle 3. Spring Pressure 10. Nut Adjusting
support and front axle to prevent the tractor 4. Plate Pressure 11. Spring
pivoting. 5. Lever Release 12. Plate Driven 123
6. Pin Release Lever
r) Remove the bolts holding clutch housing.
7. Yoke to Release Lever
s) Raise the jacks of special service tool
MST-H1/2-MP-1 until they bear the load then
The block must be positioned in such a
seperate engine from clutch housing.
manner that the cover is free to move
t) Punch the mark the clutch housing and fly downwards when pressure is applied.
wheel to ensure that the clutch is installed
4. Having compressed the clutch.
in its original position.
Unscrew the three staked adjustment nuts
u) Remove the cap screws securing the clutch
(10-3) then slowly release the clamping
cover assembly to the flywheel. (for single
pressure.
plate clutch ref. fig (1-1) & dual clutch ref.
fig. (1-2) 5. Lift the cover (2-3) and the thrust springs off
the pressure plate (Refer Fig. 3)
v) Lift the clutch assembly off the fly wheel and
remove the transmission driven member. NOTE : Mark the thrust spring to ensure they are
installed in their original positions.
NOTE : Loosen each of the bolts securing them a
turn at a time by diagonal selection until the 6. Remove the anti rattle springs (11-3) form the
pressure of the clutch springs is relieved. cover.
(This operation should be done carefully to 7. Lift the tip of the release lever (5.3) and slide
avoid distortion of the cover plate.) out the pin release cover (6.3)
4. DISMANTLING 8. Lift the release lever as far as possible then
a. THE SINGLE PLATE COIL CLUTCH lift the yoke (9-3) and lever from the hole in
the pressure plate.
1. Remove the lever plate by disengaging the
retainer ref. fig.3. 9. Remove the release lever and the release
lever pin from the yoke.
2. Punch mark the cover plate and pressure
plate to ensure re-assembly in their original 5. CLEANING, INSPECTION AND REPAIR
position. a. Wash all parts thoroughly, except the clutch
3. Place the assembly on the bed of a hand or facings, in a cleaning solvent and blow dry
hydraulic press with blocks under the pressure with compressed air.
plate (4-3). b. Inspect the clutch release levers for wear.

6. ASSEMBLY
a. THE SINGLE PLATE CLUTCH
1. The following part must be lubricated during
assembly, with a light smear of grease :
Release lever pins, contact faces of the yoke
seats in the clutch cover, drive lug sides on the
pressure plate and the plain end of the yoke.
Fig. 4 NOTE : Care must be taken to ensure that grease
does not contact the friction faces or the
c. Inspect the clutch springs for indication of
driven member.
heat or corrosion.
2. Fit the yoke to into the yoke then place a
NOTE : Clutch springs should always be replaced in
release lever (5-3) over the yoke.
sets. Never individually.
3. With the tip of the lever held up insert the
d. Inspect the facing of the driven member. If
yoke into the hole in the pressure plate and
badly glazed, burnt, oil soaked or worn,
slide in the pin (7-3) with the smooth side
replacement is necessary.
against the lever and the two projections
e. Check the hubs of the driven members for located either side of the pressure plate lug
excessive wear. Loose rivets, excessive wear insert cotter pin and split if. Carry out as
at this point is an indication of possible clutch above for remaining levers.
misalignment. Replace, if necessary.
NOTE : Thrust springs must be assembled in their
124 f. Inspect the steel discs of the driven members original positions. Marking is as described in
for cracks. If cracked, a new driven member ‘Dismantling’ para 4-4a 2.
must be installed. Check the vibration
4. Place the pressure plate under a press as
dampener springs of the driven members and
described in Dismantling and place the thrust
see if they are loose or broken or have taken
springs (3-3) on the bosses of the plate.
a set through heat. If any doubt exists,
replace the driven member. 5. Assemble the anti-rattle spring (11-3) into the
cover and then place the cover on the
g. Inspect the pressure plates for warping or heat
pressure plate aligning the punch marks.
cracks. To check the pressure plates, place
a straight edge across the pressure plate and NOTE : New adjusting nuts must be used in
if a 0.15mm feeler cab be inserted anywhere assembly of the clutch.
between the plate and the straight edge the 6. Compress the clutch until the threaded ends
plate must be replaced. of the yoke appears through the holes in the
h. Check the clutch release bearing, sleeve and cover then screw on the adjusting nuts
carrier for wear. (4-1).
i. Inspect the clutch shafts for wear, try the 7. Remove the pressure after all three adjusting
hubs of the driven members on the shafts nuts are in position.
and check that, both slide freely but without 8. Place the lever plate (1-3) on the release lever
excessive play. Excessive wear of the clutch and assemble the retainers.
shaft splines is an indication of possible 9. Adjust the lever height settings as detailed
clutch misalignment. The clutch shaft should in para 8a. “ADJUSTMENTS” and stake the
be a snug fit in the clutch shaft pilot bearing. adjusting nuts securely into the slot of the
If the bearing is worn, remove it with an eye bolts.
extractor and install a new bearing.
j. Inspect the flywheel for signs of scoring. 7. INSTALLATION
Place a straight edge across the machined a. THE SINGLE PLATE CLUTCH
face of a flywheel and if a 0.15mm feeler cab 1. A pilot tool which will slide through the bore
be inserted anywhere between the flywheel of the driven member and locate in the pilot
face and straight edge in any of the checking bearing of the flywheel will aid installation of
positions repairs or replacement is necessary. the clutch. Fig. 6 shows such a pilot tool for

installation of the dual drive clutch. b) By means of the adjusting nut (4-1) adjust
NOTE : The end of a transmission shaft will serve for the height of the release lever plate from the
the single clutch. or a special tool is flywheel or servicing fixture face to 64.52mm/
available. See special tool list. 60.20mm. see fig.7 & 8.
2. Lift the clutch assembly with driven member, c) Run out on the release lever plate must not
and position it on the flywheel dowel (3-1) exceed 0.381mm.
with the pilot tool located in the pilot bearing
in the flywheel.
3. Align the punch marks on the cover and
flywheel then insert and tighten the securing
cap screws and lock washers.
125
Fig. 7
NOTE : After setting the release lever height operate
Fig. 6 the clutch a number of times in the servicing
fixture or under hand press, then re-check the
NOTE : The clutch securing capscrews should be
lever height and readjust if necessary.
tighten a turn at a time by diagonal selection
until secured to avoid distortation of the cover d) When the adjustment has been completed,
flange. secure the locknuts by staking each into the
slot in the eye bolt.
4. Withdraw the pilot tool.
9. REMOVAL
5. Installation is now the reversal of the
“REMOVAL” procedure. a. THE CLUTCH RELEASE MECHANISM
6. To adjust the clutch pedal height and pedal (Single Plate Clutch)
free movement refer to the operator’s manual. 1. Complete ops. 1-8 in para 3a. “SINGLE
8. ADJUSTMENTS PLATE CLUTCH”.
a. THE SINGLE PLATE CLUTCH 2. Loosen the pinch bolts (1-10) from the clutch
pedal.
1. Release Lever Height
3. Remove the pinch bolts (3-10) from the clutch
a) Mount the clutch assembly on a flywheel or
release fork (4-10).
service fixture with the driven member or
spacers (8.43mm thick) in position. If the NOTE : One pinch bolt retains the key.
original driven member is being re assembled
and it is appreciably worn, the adjustment 4. Remove the pedal return spring, cotter pin (8-
must be carried out using a new member or 12) and washer, then slide the clutch shaft
spacer. from the pedal and out through the right hand
side of the housing.

Clutch finger height gauge

Adjust all fingers to just touch
Fig. 8
5. As the shaft slides out, the release fork and

release bearing assembly can be removed
from the transmission drive shaft.
c. ANTI FRICTION RELEASE BEARING
1. An antifriction thrust bearing (9-11) is fitted
over a hollow cylindrical sleeve (10-11) which
is freely supported inside the Sleeve carrier
126 Fig. 10
(13-11). It is bolted to the top machine
surface of the clutch housing (4-11). Spacer
pegs (11,12-11) used to maintain centrality of
the sleeve. Sleeve carrier hub has grease
retention zone in between rod supporting
(13-11).
2. See fig.11 for lugs rounded for the release
form (8-11) fork and another lug on the bottom
side of sleeve (10-11) to hitch sleeve return
spring (15-11). Which is fixed on it’s other
end to a sheet metal bracket (14-11) bolted
on the carrier (13-11).
10. DISMANTLING
The release bearing (single plate clutch)
1. Remove the retainer springs (3-3) to remove
the bearing cup assembly from the release
fork.
11. ASSEMBLY
1. Assembly is the reversal of the Fig. 11
“DISMANTLING” procedure. 1) Bracket 8) Fork clutch release
2) Bracket clutch pedal 9) Bearing antifrication
12. INSTALLATION return spring 10) Sleeve clutch release
1. Installation is the reversal of the “REMOVAL” 3) Plate holding brg. 11) Peg support brg.
carrier carrier (large)
procedure. 4) Clutch housing 12) Peg support brg.
NOTE : 5) Shaft clutch release carrier (small)
6) Circlip 13) Bracket sleeve carrier
1. Tighten the clutch fork pinch bolts to the
7) Key clutch release 14) Bracket spring holding
specified torque as detailed in specifications
15) Spring return clutch
para 2 torque loading.

2. Lubricate the clutch bearing sleeve as
detailed in the “Operator’s manual”.
3. The clutch pedal should be adjusted to give
a measurement of 152.4mm" between the
pedal pad and the foot plate. This
measurement is achieved by adjusting the
set screw (fig.-9) until the required
measurement is obtained with the clutch fully
engaged the pedal should have a free
movement of 25.4mm-50.8mm The correct
free movement is obtained by loosening the
retaining bolt (fig.-9) and move the pedal round
the clutch release shaft until the required
adjustment has been made. Ensure the
retaining bolts are securely tightened. For the
Dual clutch the height of the clutch pedal
above foot plate should be kept at 177.8mm
with a play of 12.7mm Adjustment of pedal
is same as explained above.
127

Clutch - Single & Dual Plate Diapraghm
2. SINGLE PLATE DIAPRAGHM CLUTCH

The single plate clutch is a foot operated dry
plate type. It consists of a driven plate assembly,
cover assembly and a release bearing assembly.
The driven plate assembly is clamped between
the flywheel rear face and the cover assembly
which is bolted to the flywheel.
128
Fig. 1
The cover assembly is composed of compress

steel cover, a diaphragm, a pressure plate, a
belleville washer, return spring and antidrop rivets
and clutch assembly mounting bolts with washer.
The pressure plate is bolted to the flywheel. The
diaphragm is made of spring steel, a flat spring
Fig. 3
or belleville washer fingers are cut out in the 1. Clutch housing 5. Pin
center. When assembled to the cover the 2. Pressure plate 6. Pivot
diaphragm is tensioned and load the pressure 3. Diaphragm spring 7. Tangential drive
plate. strap
4. Ring 8. Balance hole
Fig. 2

A tangential drivestrap (7-3) maintain the off driven members, thus breaking the drive
diaphragm against the fulcrum in the cover (C P to the power take-off shaft.
type cover). The pressure plate is held against 3. REMOVAL
the diaphragm by return spring. The return springs 1. To remove the clutch engine must be separated
are fasten by rivets (6-3) to the cover and from the clutch housing. Apply parking hand brake
pressure plate. Antidrop rivets are provided to and wedge to rear tyre.
prevent excessive movement of pressure plate.
2. For spliting the tractor between clutch housing and
c. DUAL DRIVE CLUTCH engine as detailed in “spliting the tractor”.
The dual clutch provides both transmission & 3. Punch the mark the clutch cover and flywheel to
power take-off with a independent driven member. ensure that the clutch is installed in its original
Power disengagement is done in two phases. In position.
first phase, power to transmission is cut-off while 4. Remove the cap screws securing the clutch cover
the supply to P.T.O. gear box continues and in assembly to the flywheel for single plate clutch
second phase power to P.T.O. gear box as well ref. (fig.1) & dual clutch ref. (fig.2).
is cut-off. 4. DISMANTLING
The dual clutch assembly consist of: a) Gently pierce out (by drilling) both end of the
1. Housing drive strap rivet and remove pressure plate from
2. Main drive pressure plate the cover assembly.
3. P.T.O. pressure plate. NOTE:
4. Diaphragm spring 1. Ensure that the hole on the pressure plate
and cover are not damaged. 129
5. Main drive plate
2. Before doing drilling operating clamp the job
(with sintered metal pads and torsion damper)
properly to avoid movement.
6. P.T.O. Plate
Use service fixture as shown in the figure to
7. Main drive release arm/lever do the assembly of pressure plate and drive
8. P.T.O. release arm strap use press to rivet the drive strap and
9. Release bearing assembly pressure plate securely.
The two driven member are splined to their b) Pierce out (by drilling) cover rivets and remove
respective shafts, the main shaft running pressure plate sub assembly.
through the hollow power take off shaft. Two c) Then gently pierce out (by drilling) delta rivet
belleville springs, one positioned between the riveted head and remove diaphragm.
main driven pressure plate and the fly wheel
for main drive, and between the power take- 1. Before doing drilling operation hold cover assy.
off pressure plate and outer cover for power properly to avoid movement and also care should
take-off drive, load the respective drive be taken to avoid deformation on cover by excess
member. load.
The outer cover carries six clutch release 2. During drilling operation the holes on the cover
levers, to which a release ring is mounted, should not get disturbed or enlarged.
and this is depressed by a ball thrust
3. Fit some of the bolts remove the guide studs if
bearing actuated by conventional pedal
used, fit the remainder of the bolts and tighten
operation.
them to specified torque.
Partial depression of the clutch pedal
4. Reverse procedure ‘a to m’.
releases the main drive pressure plate from
the main drive clutch driven member, thus 5. Adjust the clutch linkage.
breaking the drive to the transmission. Further 6. Check power steering reservoir oil level. if fitted.
depression of the pedal moves the main drive Replacement of facing
pressure plate further away from the engine Friction facing can be replaced by removing rivets by
fly wheel until six adjustable set screws drilling. Use new set of facing and rivet it with cushion
contact the power take-off pressure plate, disc by riveting anvil. Ensure that all the rivets are
further movement releases the power take- properly riveted. Keep the disc assy. on between

centers and check the face out of disc assembly. anywhere between the flywheel face and straight
Face out should be within 1.0 mm. edge in any of the checking positions repairs or
NOTE: replacement is necessary.
1. Check for marks or digging of facing rivet on i. Machining can be made without disassembling the
to pressure plate and flywheel face, if so clutch cover. Care to be taken to prevent the
remachine flywheel face remachine pressure burrs entering into the assembly.
plate. Machining can be done without Remove 1.0 mm material from pressure plate face
dismantling the clutch cover assy. care to be and it can be removed in the three phase two
taken to prevent the burrs entering into the rough cut and one final finishing cut and then
assembly. verify below 4 check points. If all the check points
2. Remove 1.0 mm material from pressure plate are OK, then use the cover assy. as it is.
face final finishing cut and then verify at H NOTE :
pointing. If all the check points are OK then 1. Too much pedal travel excessively loads the
use cover assy. as it is. release bearing against thrust spring and
5. CLEANING, INSPECTION & REPAIR reduced travel can result into slippage of
a. Wash all parts thoroughly, except the clutch clutch plate.
facings, in a cleaning solvent and blow dry with 2. Due to wear of lining, pedal play can reduce
compressed air. over a period of time because of lifting up
b. Inspect the facing of the driven member. If badly release plate. Re adjustment should be done
glazed, burnt, oil soaked or worn, replacement is to avoid excessive wear of release bearing
130 necessary. & Date.
c. Check the hubs of the driven members for
excessive wear. Loose rivets, excessive wear at
this point is an indication of possible clutch
misalignment. Replace, if necessary.
d. Inspect the steel discs of the driven members for
cracks. If cracked, a new driven member must
be installed. Check the vibration dampener springs
of the driven members and see if they are loose
or broken or have taken a set through heat. If any
doubt exists, replace the driven member.
e. Inspect the pressure plates for warping or heat
cracks. To check the pressure plates, place a
straight edge across the pressure plate and if a
0.15mm feeler cab be inserted anywhere between Aligning
Tool
the plate and the straight edge the plate must be
replaced. Fig. 4
f. Check the clutch release bearing, sleeve and 6. ASSEMBLY
carrier for wear.
Use service assy. fixture as shown in the figure to
g. Inspect the clutch shafts for wear, try the hubs assemble diaphragm to cover preferably use the press
of the driven members on the shafts and check for riveting.
that, both slide freely but without excessive play.
a) Assembly of diaphragm
Excessive wear of the clutch shaft splines is an
1. Place the diaphragm over the fixture as
indication of possible clutch misalignment. The
shown in the fig.6.
clutch shaft should be a snug fit in the clutch shaft
pilot bearing. If the bearing is worn, remove it with 2. Slots in the diaphragm should passes through
an extractor and install a new bearing. the delta rivet.
h. Inspect the flywheel for signs of scoring. Place NOTE : Apply high temperature grease over the
a straight edge across the machined face of a belleville area of diaphragm spring both
flywheel and if a 0.15mm feeler cab be inserted side.

3. Place the cover plate to keep it on the 4. There should not be any gap after fully
diaphragm and tighten the cover plate against tightening the cover plate.
outer ring. 5. Preferably use press to rivet the delta rivet.
6. Then loosen the mounting bolts and rotate the
inner plate and keep the delta rivet for
riveting. See fig.7.
The 9 rivets should be assembled on three stages.
Then assemble the pressure plate subassembly into
cover subassembly by riveting. The stage process are
explained below :
1. Place the outer ring properly on the table.
2. Place pressure plate rivet correspondingly as
shown in fig.9.
3. Take 4 nos. of drive strap together and insert it
to the pressure plate rivet as shown.
4. By using alignment screw, screw it into the ring
as shown (Fig.10). This is mainly to avoid
dislocation all straps. The above process is for
all the 3 locations.
Fig. 5
131
Fig. 9
Fig. 6
Fig. 7 Fig. 10

Fig. 11
Fig. 12
5. Insert pressure plate on to the pressure plate rivet
as shown in fig.11.
6. Use hand press to press all the pressure plate
rivet.
132 7. Unscrew the alignment screws and take out
pressure plate sub. assy.
NOTE :
1. Drive strap should not rotate freely after
riveting.
2. Riveted (formed) head diameter should be 10
to 11 mm.
8. Take 3 bushes and fix it on the outer ring fixture.
9. Keep the pressure plate fixture accordingly as
Fig. 13
shown in fig.12.
10. Take pressure plate sub. assy. and keep it over 7. INSTALLATION
the fixture as shown fig.13. a. THE SINGLE PLATE CLUTCH
11. Ensure that whether the drive straps are properly 1. A pilot tool which will slide through the bore of
seated over rivet. the driven member and locate in the pilot bearing
12. Place the cover & diaphragm sub-assy. over the of the flywheel will aid installation of the clutch.
pressure plate sub-assy. Then tighten the cover Fig.4 shows such a pilot tool for installation.
sub-assy. against the outer ring. NOTE : The end of a transmission shaft will serve for
13. Cover the mounting holes locations are marked the single clutch, or a special tool is
thus (fig.14). available. See special tool list.
14. Use press to rivet the cover. 2. Lift the clutch assembly with driven member, and
Finally loosen the mounting screws and take out position it on the flywheel dowel with the pilot tool
clutch assy. located in the pilot bearing in the flywheel.
NOTE : 3. Align the punch marks on the cover and flywheel
then insert and tighten the securing cap screws
1. There should not be any gap between cover
and lock washers.
to fixture during assembly.
NOTE : The clutch securing capscrews should be
2. No gap between drive strap and rivet head
tighten a turn at a time by diagonal selection
after riveting.
til secured to avoid distortation of the cover
3. Form riveted head dia 10-11 min. flange.

4. Lift off the cover/housing (1-16) and take out main

drive pressure plate (2-16) then remove diaphragm
spring (4-16) P.T.O. pressure plate (3-16).
5. Loosen the adjust nut (12-16) which are holding
P.T.O. pressure plate (3-16) grade all release the
clamp pressure and take out pressure plate and
P.T.O. Drive plate.
NOTE : Do not loosen the 3 nut on the P.T.O. Plate.

c2. INSPECTION
1. Check the flywheel face is free from scores and
crack when machining the surface.
Fig. 14 2. Check the main drive plate and P.T.O. drive plate
sintered metallic pads and torsion damper. For
wear and crack if inspection proves necessary to
replace.
3. Check the condition of pilot bearing if replace
necessary.
4. Check the condition of the engine oil seals on the
engine and transmission side for leaks and
replace if necessary. 133
Pay special attention to oil seals fitted between
hollow and main drive shafts on the transmission.
c3. ASSEMBLY
1. The following parts must be lubricated during
assembly with a light smear of grease.
Fig. 15 a) Driving lug of P.T.O. pressure plate.
b) Driving lug of main drive pressure plate.
4. Withdraw the pilot tool.
c) Apply the grease to the main drive shaft,
5. Installation is now the reversal of the “REMOVAL” remove surplus grease.
procedure.
6. To adjust the clutch pedal height and pedal free 1. Housing
movement refer to the operator’s manual. 2. Main drive pressure plate
3. P.T.O. pressure plate
c. DUAL DRIVE CLUTCH
4. Diaphragm spring
c1. REMOVAL 5. Main drive plate (with sintered
1. In order to facilitate reassembling the clutch in metal pads and torsion damper)
its correct balanced position the following items 6. P.T.O. plate (with organic
facinga nd rigid centre)
should be marked with center punch.
7. Main drive release arm
a) Outer cover (Housing) 8. P.T.O. release arm
b) Power take-off pressure plate 9. Flywheel
c) Flywheel plate 10. Eye bolt
11. Release arm control
d) Main drive plate
12. Adjusting screw
2. Place the clutch in a fixture clamp plate across 13. Lock nut
the outer case / housing. Tighten down plate until 14. Adjusting nut
the clutch levers are free or alternatively use a 15. Roll pin
hand or hydraulic press. 16. Anti-rattle spring
3. Loosen the adjust nut (14-16) three nut which hold 17. Pivot pin
the main disk pressure (2-16) gradually release
the clamp pressure. Fig. 16

NOTE :
1. Hubs which are nickel plated must not be
lubricated.
2. Care must be taken to ensure the grease
does not contact the friction face or the driven
member.
2. Place clutch housing (1-16) on a table then insert
a lever assembly eye bolt (10-16) in hole. (See
fig. 16 & 17)
3. Insert 6 lever spring i.e. anti rattle spring and
pivot pin taking care that the hole on the clutch
housing and pin hole align properly.
Fig. 19
4. Insert lock pin and push it in by hammer. Fix all
the six levers in housing. 6. Place the P.T.O. Drive plate see fig.19.
NOTE : Three release arm for P.T.O. with shorter (13- 7. Place the pressure plate (3-16) see fig.20 (4-20)
16) eye bolts and three longer eye bolts, and place the wire ring (5-20).
release arm (14-16) for holding main drive 8. Place the diaphragm spring (5-20). Then place the
pressure plate (2-16). main drive pressure plate, (4-22) then fixture plate
5. Invert the housing and place it on fixture see to compress press plate down and fix the
fig.18.
134
1
4
3
2
Fig. 20
1. Clutch Housing 3. Eye bolt release lever shorter
Fig. 17 2. Eye bolt release 4. Pressure plate P.T.O.
1. Clutch Housing 3. Release arm lever liner 5. Ring
2. Pivot Pin 4. Locking Pin
3
2
2 1
5
2
5 3
4 1
Fig. 21
1. Fixture Fig. 18 4. Main Drive Pressure 1. Clutch Housing 3. Eye bolt shorter release lever
2. Housing plate eye bolt 2. Eye bolt longer 4. Pressure plate P.T.O.
3. Aligning dolly 5. Release lever release lever 5. Diaphram spring

4 2 5 1 3
Fig. 22 Fig. 23
1. Clutch Housing 4. Plain drive pressure plate
NOTE :
2. Eye bolt longer 5. Fixture
3. Eye bolt shorter 1. The clutch housing cap screws should be
tightened one turn at a time by diagonal
3 nuts (14-16) see fig.15 to hold the pressure plates section until secured to avoid distortion the
in place. cover. See fig. 25.
9. Adjust the height of the levers for the specified 2. For details of special tool see specification
lever height. (See fig. 23) and “ADJUSTMENT” para . 135
para b5. ADJUSTMENT
c4. INSTALLATION c5. DUAL DRIVE CLUTCH
1. Using a special clutch alignment tool. Insert the
1. To adjust the release lever height, mount the
pilot tool through the clutch assembly and place
clutch assembly on the flywheel or service fixture
the main driven member on the pilot with the
with driven member in position.
smaller end of the boss towards the flywheel.
NOTE : Ensure that P.T.O. plate is aligned to the pilot
2. Lift the clutch assembly into position on the inside
bearing in the crank shaft this is necessary
of the flywheel rim with the pilot tool in the
for aligning the P.T.O. drive shaft spline later.
flywheel bearing. See fig.4.
2. Tighten the flywheel bolts at specified torque and
3. Align the punch mark on the cover and flywheel
then insert and tighten the securing cap screws adjust the main levers by tightening the main disc
and lock washer. pressure plate lock nuts.
4. Withdraw the pilot bearing. To set the levers compare them with the P.T.O.
levers. The main levers should be set 8 mm
5. Align the engine with the gear box, two guide
higher than the P.T.O. levers.
studs will assist its alignment.
6. Turn the flywheel and, at the same time push the
engine and front axle towards the transaction.
Turning the flywheel align the clutch plate splines
with the gear box and P.T.O. input shaft continue 1
pushing and turning until the engine flanges meet.

NOTE : Do not force, fit and tighten any of the bolts
until the two flanges meet, or serious damage
may occur to the transaction and clutch.
7. Installation is now the reversal of the “Removal” 2
procedure.
8. Adjust the clutch pedal hight and pedal free
3
movement refer to the OPERATOR’S MANUAL.
Fig. 24
1. Flywheel 2. Clutch assembly 3. Clutch aligning tool

3. Remove the assembly from the flywheel and lock 3) Remove the flexible pipe, flexible clip and coupling
the main disc nuts in position. nut.
NOTE : Ensure this is done correctly and ring is 4) Remove the punch bolts (3-26) and key clutch
flattened against the flats on the eye bolt. lever (5-26) from the clutch lever fork (4-26).
5) Remove circlip (7-26) from the clutch shaft
4 (6-26). Then slide out the clutch shaft through the
5
1 right side of the housing.
6) As the shaft slide out the release bearing
8
11 assembly can be remove from the transmission.
7) Remove the thrust bearing (13-27) from the clutch
release sleeve (14-27).
9
10 9. ASSEMBLY
Assembly is the reversal of the “Dismantling”
procedure.
7 12
6 2
3
Fig. 25
8. REMOVAL
136
a. The clutch release mechanism
1) Complete operations 1 & 2 as in para 3.
2) Loosen the punch bolts (1-26) from the clutch
pedal connecting link bracket.
Fig. 27
1. Housing clutch 16. Bracket spring holding
2. Circlip 17. Washer 5/16" spring lock
3. Fork clutch release 18. Bolt
2 4. Bolt clutch release fork 19. Pad sealing clutch
8
5. Washer 5/16" spring lock housing hand hole
4 6. Key clutch lever 20. Cover hand hole housing
7 7. Shaft clutch release 21. Bolt 3/8" UNCx3/4" hex.
8. Nipple grease Hd.
5 3 5 1 9. Washer plain 22. Pad rubber clutch
10. Pipe grease nipple housing dust cover
11. Bolt M12x1.5x90 hex hd 23. Cover dust clutch
12. Washer copper housing cpte.
13. Bearing antifriction clutch 24. Bolt
6
14. Sleeve clutch release 25. Bolt
15. Spring retaining cluch 26. Bolt
release brg 27. Bolt
Fig. 26

(7-29) from the clutch pedal (2-29) and at the

clutch shaft lever (4-29).
3) Remove the cotter pin (8-29) from the clutch
pedal shaft bracket (1-29).
Remove the cotter pin and washer from
connecting link (3-29) then tap clevis pin from the
lever clutch shaft (4-29).
Remove the six capscrews and look washer
(9-29) securing the clutch pedal bracket (1-29) to
transmission housing.
b. Cleaning, Inspection & Repair
1) Wash all parts in a suitable cleaning solvent.
2) Inspect the pedal, bracket shaft and linkage
for wear or cracks.
c. The clutch pedal assembly
‘Assembly’ is the reversal procedure of
dismantling.
137
Fig. 28
1 Housing Clutch Cpte. 13 Gasket Clutch Housing
2 Nipple Grease Bottom Cover
3 Circlip 14 Bolt
4 Shaft Clutch Release 15 Cover Hand Hole
5 Fork Clutch Release 16 Pad Seal Cl. Hsg Hand
6 Key Clutch Lever Hole Cap
7 Bolt Clutch Release Fork 17 Bolt
8 Washer Spring 18 Dust Cover
Lock 5/16" 19 Pad Rubber Dust Cover
9 Sleeve Clutch Release - 20 Bolt
Crpto 21 Bolt
10 Bearing Clutch Release 22 Bolt
11 Insert Bush Clutch 23 Bolt
Release Fork 24 Gasket Clutch Housing
12 Cover P.t.o Gear Cover To Transmission
2
10. INSTALLATION 4
Installation is the reversal of the “Removal”
procedure. 5
3
NOTE : 1. Tighten the clutch fork pinch two bolts 1
after inserting key clutch lever and spacer
9
in between fork release and tighten to
7
specified torque as detailed in
specifications para. 6
2. Lubricate the bearing sleeve as detailed
8
in the “Operators Manual”.
9. CLUTCH PEDAL & CONNECTION 10
a. Removal Fig. 29
1. Clutch pedal bracket 6. Washer
1) Disconnect the pedal return spring (5-29). 2. Clutch Pedal 7. Pin
2) To remove the link connecting remove the 3. Link connecting 8. Cotter pin
4. Clutch shaft lever 9. Bolt
cotter pin and washer then tap the clevis pin 5. Pedal return spring 10. Shaft

Clutch - Trouble Shooting
3. TROUBLE SHOOTING
A. Clutch not disengaging (1) Clutch pedal free (1) Adjust

ply excessive
(2) Dust / Rust on clutch disc (2) Remove Rust
generated from facing
(3) Release fork broken (3) Replace
(4) Clutch disc or pressure (4) Replace
plate wrapped
(5) Pressure plate worn or (5) Replace pressure plate
broken assembly
B. Clutch slips (1) Clutch pedal free ply too legs (1) Adjust
(2) Clutch disc excessive worn (2) Replace
(3) Grease or oil on clutch (3) Replace
disc facing
plate wrapped
138 (5) Diaphragm spring weaken (5) Replace
or broken
(6) Pressure plate worn (5) Replace pressure plate
or broken assembly.
C. Chattering (1) Grease or oil on clutch (1) Replace

facing drive plate
plate wrapped drive plate
(3) Clutch disc boss spline worn or (3) Replace or Remove
Rusted or gear shaft spline worn Rust; Replace
(4) Gear shaft bent (4) Replace
(5) Pressure plate or flywheel (5) Replace
face cracked or scored or if admissable take fine cut.
(6) Diaphragm spring strength un- (6) Replace
even or diaphragm spring broken
D. Rattle during running (1) Clutch disc/drive plate boss (1) Replace
spline worn
(2) Thrust ball bearing worn or sticking(2) Replace
E. Clutch squeals (1) Thrust bearing sticking or dry (1) Replace or lubricate
(2) Clutch disc excessively sticking (2) Replace
(3) Excessive driveline (3) Find correct cause of
torsional activity torsional activity
F. Vibration (1) Gear shaft bent (1) Replace

(2) Clutch disc rivet worn or broken (2) Replace
(3) Clutch parts broken pilot (3) Replace
bearing worn or damage

GROUP - 6
Transmission
Chapter 1 - Sliding & Partial Constant Mesh
Chapter 2 - Differential
Chapter 3 - Power Take offs (Standard & C.R.P.T.O.)
1st Version 3rd set.pmd 139 6/3/2006, 11:18 AM

Transmission - Chart
140

Transmission - Sliding & Partial Constant Mesh
Chapter-1 Sliding & Partial Constant Mesh

Specification
Description
Removal of Transmission
Sliding & Partial Constant Mesh Transmission Dismantling & Assembly
Sliding & Partial Constant Mesh Gear Shifter Housing Dismantling & Assembly
Trouble Shooting
141

GENERAL
142
Fig. 14 - Cross section of the eight speed Transmission Standard PTO
1. Spline shaft 19. Driving shaft bearing

2. Spline shaft rear bearing 20. Circlip
3. Spacer 21. 011 seal
4. Spline shaft front bearing 22. Bearing cage
5. Shims 23. Bearing retainer
6. Bearing cage 24. Securing capscrew
7. Locknut 25. Lockplate
8. Lockwasher 26. Retaining washer
9. Locknut 27. Countershaft front bearing
10. 1st and reverse sliding gear 28. Spacer
11. 2nd and 3rd sliding gear 29. Bush
12. 4th and direct coupling gear 30. Constant mesh gear
13. 4th and direct speed sliding gear 31. Sliding gear coupling
14. Sliding quill gear 32. 3rd and 4th driving gee,
15. Sliding gear coupling 33. 2nd speed driving gear
16. Pilot bearing and spacer 34. Keys
17. Transmission driving shaft 35. Countershaft and 1st gear
18. Circlip 36. Countershaft rear bearing
37. Circlip

1. SPECIFICATIONS
O.D. (for quill gear) (mm) ... 34.91 — 34.92

O.D.(for pilot bearing) (mm) ... 25.4 — 25.38
Quill gear I.D. (mm) ... 41.26 — 41.28
Needle roller bearings l.D. (mm) ... 34.92
Needle roller bearing O.D. (mm) ... 69.88
Countershaft bush O.D. (mm) ... 69.78 — 44.40
Constant mesh I.D. (mm) ... 69.85 — 69.88
Reverse idler shaft bushes (ream size)
Front I.D. (mm) ... 31.83 — 31.87
Rear I.D. (mm) ... 25.22 — 25.27
TORQUE LOADINGS
Countershaft bearing retainer nut (Nm) ... 40.67 — 47.45
Splined shaft cage retainer nut (Nm) ... 70.5 — 79.99
Spline shaft taper roller bearing (Pre-load) (Nm) ... 6.78 — 20
143

8 + 2 Speed Gear Box ( Power Train)
144

2. DESCRIPTION
The Mahindra Tractor Transmission Provides eight
forward and two reverse speeds. Ball and roller bearing
are fitted through out except for the transmission spline
shaft pilot bearing. Sliding quill gear bearing and
reverse idler gear bearing which are needle roller type,
and also the reverse idler is provided with bronze bush
at one side.
The Transmission driving shaft is Supported at the
rear by a single row ball bearing; which is housed in
a cage bolted to the front of the transmission case.
The front end is mounted in a pilot bearing located
in the engine crankcase.
Drive is transmitted to the counter shaft through the Fig. 1 - Neutral Position
helical constant mesh gear train. The pinion is Integral
with the transmission driving shaft and the gear runs
in a grey iron bushing.
Incorporated in the constant mesh gear is a splined
coupling for the low ratio Sliding gear coupling which
engages with the third and fourth speed driving gear
dog and Transmits power through the counter shaft
to the selected gears.
The Transmission splined shaft is supported by two
taper roller bearings at the rear and a needle roller
bearing at the front which is housed in a bore in the
rear of the transmission drive shaft. A sliding quill gear
145
which carries the fourth and direct speed sliding and
a high range coupling runs on needle roll bearings
between the splines and a spigot on the spline shaft.
The reverse idler shaft runs in bushing and needle
bearing mounted in the transmission case. The drive
gear which is in constant mesh with the counter shaft
is part of the shaft it self. The drive to the spline shaft Fig. 2 - Low Neutral
has integral splines which mate with those on the
shaft. Lubrication of the transmission is accomplished
by the counter shaft gears running in oil and splash
lubricating the spline shaft and driving shaft
assemblies. One additional plastic gear is also fitted
specifically to lubricate spline shaft bearing while
tractor is towed.
Fig 1-13 illustrate the transmission drive Train in
NEUTRAL, LOW NEUTRAL, LOW REVERSE, LOW
FIRST, LOW SECOND, LOW THIRD, LOW FOURTH,
HIGH NEUTRAL, HIGH REVERSE, HIGH FIRST,
HIGH SECOND, HIGH THIRD, HIGH FOURTH
respectively. Fig 14 shows across section of the eight
speed basic transmission.
Thus two type of gear shifting mechanisms are used.
One for sliding mesh transmission see fig. 27. Two for
partial constant mesh Transmission see fig. 33.
1. Shifter for Sliding mesh transmission
Fig. 3 - Low Reverse Gear Engaged

Fig. 4 - Low 1st Gear Engaged FIG. 7 - Low 4th Gear Engaged
146
Fig. 5 - Low 2nd Gear Engaged FIG. 8 - High Neutral
Fig. 6 - Low 3rd Gear Engaged FIG. 9 - High Reverse Gear Engaged

This type of shifting has been widely used in

Mahindra Tractor.
2. Partial constant mesh shifter mechanism it consist
of two piece assembly instead of one piece as
in case of sliding mesh transmission.
The lower piece, also called housing of transmission
case cover front, is bolted on the transmission case
and acts as a spacer between the transmission case
and the shifter cover. This arrangement enables the
removal of shifter unit without disturbing the hydraulic
FIG. 10 - High 1st Gear Engaged
housing.
3. REMOVAL
a. 1. Disconnect the battery earth lead.
2. Drain the oil from the transmission and P.T.O
Housing.
3. Disconnect the rear light cable from the
Instrument panel or separate wiring connector
socket.
4. Remove the covers from the clutch and
P.T.O. Compartments of the clutch housing.
There is only one cover when standard P.T.O
is fitted.
5. Disconnect the high and low pressure pipes
FIG. 11 - High 2nd Gear Engaged
from the Hydraulic pump or Housing. The
Hydraulic lift Housing need not be drained if 147
corks are quickly fitted into the pipe ends.
6. Securely support the rear of the tractor under
the transmission case and the front of the
tractor under the clutch Housing on suitable
wheel Jack / wooden blocks.
CAUTION : The rear wheel must be locked and
wooden wedges positioned between the front axle
support to prevent pivoting.
7. Remove the capscrew securing the L.H. Foot
plate bracket to the capscrews attaching the
clutch to the transmission case.
FIG. 12 - High 3rd Gear Engaged
NOTE : on the standard P.T.O version, six capscrews
(1-17) are located inside the clutch housing
and two out side. On the constant running
P.T.O. version six cap screws are located
and four inside (1-18). There are also two
dowels (5-19) located between the housing
and transmission on both version.
8. Pull the front of the tractor forward. Take care
on the constant running P.T.O. Versions that
the height of the two wheel jacks are
adjusted to ensure the main driving shaft is
withdrawn squarely from the hollow P.T.O.
Shaft. If care is not taken the shaft bearing
FIG. 13 - High 4th Gear Engaged and oil seal will be damaged.

Fig. 15
148
Fig. 16
Fig. 17
Fig. 18

Fig. 24
Fig. 20
149
Fig. 31
Fig. 21 Fig. 22

b. THE TRANSMISSION DRIVING SHAFT 3. Turn up the locking washer and remove the
(STANDARD P.T.O) nut (4-23) and washer.
1. Remove the four capscrews (3-19) scaring the NOTE : Special socket to available for removing and
bearing cage (4-19) and transmission driving installing the retaining nut (4-23).
shaft (6-19) and withdraw the Transmission
4. Remove the counter shaft bearing and
transmission driving shaft as detailed for
standard P.T.O. para.
d. THE TRANSMISSION SPLINE SHAFT.
6
1. Release electrical cables.
2. Remove Hydraulic lift housing as detailed in
“HYDRAULICS”
3. Remove the capscrews securing the shifter
housing and lift of the housing.
4. Remove the three bearing housing retainer
nuts (1-24).
5
Fig. 19
driving shaft assembly. The dog th teeth have
been shaven to facilitate removal of driving
shaft without removing counter shaft from the
150
bearing.
c. THE TRANSMISSION DRIVE SHAFT
(C.R.P.T.O)
Fig. 28
1. Remove the Rear P.T.O shaft from the rear
of the transmission case as detailed in
5. With draw the spline shaft assembly with
‘POWER TAKE OFF’
bearing (2-24) clear of the transmission case.
2. Remove four capscrews (1-23) and counter
shaft front bearing retainer (2-23). e. THE TRANSMISSION COUNTER SHAFT
1. After removing the driving and spline shaft
drive the counter shaft carefully towards the
differential compartment until the rear bearing
(1-26) is clear of the housing.
NOTE : The rear bearing can be removed with the
differential in position.
2. Remove the circlip (2-26), then pull the rear

bearing from the counter shaft.
3. Lift the counter shaft assembly clear of the
transmission case.
f. THE REVERSE IDLER SHAFT
1. Remove the right hard bull gear as detailed
in chapter “AXLE & WHEELS”.
2. From differential compartment remove the
circlip (38-27) and washer from the reverse
Fig. 23 idler shaft.

shaft, but with the C.R.P.T.O. an

additional seal seals on the P.T.O. at the
rear of the clutch housing.
3. Remove the circlip (19-27) then press the
shaft (16-27) from the bearing.
4. Remove the needle roller bearing (Pilot).
b. 1. Remove the sliding gear coupling (14-27)
sliding quill gear the fourth and direct speed
sliding coupling gear (12-27) the fourth and
direct speed coupling gear (11-27) the second
and third speed sliding gear (10-27) and the
first and reverse sliding gear (9-27) from the
shaft.
2. Press the two needle bearings from the
sliding gear if inspection proves this
necessary.
NOTE : A special Mandrel is required for the removal
and assembly of needle roller bearings.
Fig. 26 3. Disengage the lock washer (8-27) from the
3. Withdraw the reverse idler shaft and gear (1- two locknuts (7-27) remove the first locknut,
25) from the driving gear (2-25) and the washer and second locknut.
transmission case lugs. 4. Remove the spline shaft (1-27) from the
bearing cage.
5. Remove the spacer (3-27) and press the rear
bearing from the shaft. 151
NOTE : The cone of the rear bearing (2-27) and the
spacer will remain on the splines shaft and
the cone of the front bearing will be loose in
cup.
6. Press both bearing cup from the cage.
c. THE TRANSMISSION COUNTER SHAFT
1. Remove the constant mesh gear (1-29) sliding
gear coupling (2-29) then remove the grey
iron bush from the counter shaft.
2. Press the shaft from the third and fourth
Fig. 25 speed driving gear (4-29) and remove the
exposed key (5-29).
4. Remove the bushes from the lugs only if
3. Press the shaft from second speed driving
inspection proves this necessary.
speed gear (6-29) and remove the second key
NOTE : Refer to para 7a for replacing and reaming (7-29).
the reverse idler bush.
4. DISMANTLING
a. 1. Remove the circlip (17-27) press the shaft
complete with bearing from the cage (21-27).
2. Press the oil seal from the cage.
NOTE (1) : With the C.R.P.T. there are two oil seals.
NOTE (2) : With the standard P.T.O. the oil seal
seals against the transmission driving Fig. 29

4. Remove the bronze bush from the hollow 2. Check all parts for serviceability.
counter shaft (8-29) C.R.P.T.O. if inspection 3. Lubricate all serviceable bearings and wrap in
indicates that replacement holed is necessary. grease proof paper until required for re-assembly.
d. THE GEAR BOX SHIFTER HOUSING 4. Remove all gasket material from joint faces.
5. Inspect the bushes for wear or damage.
6. Inspect gears for worn chipped or broken teeth
check splines for burrs and correct fit. All gears
should slide easily on the splined shaft but not
have excessive sideplay.
7. Check the spline shaft for wear or damage.
8. Inspect the shifter rails and forks for straightness
wear of poppet recesses and freedom of
movements.
9. Check the shifter rail shaft stop plate and guides.
10. Dress off burrs on splines or gear teeth with a
fine carborundum stone, taking care to remove
the burr only.
11. Replace all unserviceable parts with new.
12. Use new oil seals ‘O’ Ring and gasket on
assembly.
Fig. 30
1. Pry out one of expansion plug (1-30).
6. ASSEMBLY
2. Using a small drift, drive the small Pivot shaft
a. THE TRANSMISSION DRIVE SHAFT
(19-34) out through the opposite side of the
152 cover; this will take the other expansion plug 1. Press the bearing (18-27) into the shaft and
with it. install the circlip.
3. Lift out the gear shifter lever (2-30) and slide 2. Press oil seal (22-27) onto the cage with the
the large pivot shaft (9-34) from the lever. lip facing in wards.
NOTE : In the C.R.P.T.O. Version install the second
4. To dismental the lever remove the ball
oil seal with the lip facing out wards.
(7-34) from the lever, remove the cotter then
slide off the spring stop (11-34) spring, felt 3. Insert the drive shaft through cage taking care
washer and shield (16-34). not to damage the oil seal.
5. Turn down the lock plates Remove the four 4. Press the shaft and bearing into cage and
capscrews (2-31) and spring (5-34) from the install the circlip.
cover. 5. Install the pilot bearing (15-27) into the driving
6. Lift out the rails and guides. shaft.
7. Remove the poppet balls and springs from b. THE TRANSMISSION COUNTER SHAFT
the cover. Assembly is the reversal of the dismantling
8. Drive the pin (3-30) from the hi-lo shifter procedure.
handle (4-30) and remove the handle, poppet c. TRANSMISSION SPLINE SHAFT
ball and spring.
NOTE : If the transmission spline shaft rear bearings
9. Drive the pins from the hi-lo shifter cam (20 or bearing cage have been replaced, the
& 25 - 34) and pull the shaft out from the bearing must be preloaded on assembly as
cover and cams. detailed in “ADJUSTMENTS” After carrying
10. Remove the oil seals from the cover. out ops. 1-5 inclusive. If the original bearings
5. CLEANING, INSPECTION & REPAIR and bearing cage are used proceed as
1. Thoroughly clean the inside of the transmission detailed above.
case and blow all oil passages clear with 1. Press both bearing cups into the bearing
compressed air. cage (5-27) small diameter first, ensuring that

153
1. Spline shaft 21. Bearing cage

2. Spline shaft rear bearing 22. Oil seal
3. Spacer 23. Circlip
4. Shims 24. Countershaft rear bearing
5. Bearing cage 25. Countershaft and 1st gear
6. Spline shaft front bearing 26. Keys
7. Locknuts 27. 2nd speed driving gear
8. Lockwasher 28. 3rd and 4th driving gear
9. 1st and reverse sliding gear 29. Sliding gear coupling
10. 2nd and 3rd sliding gear 30. Constant mesh gear
11. 4th and direct coupling gear 31. Cast iron bush
12. 4th and direct speed sliding gear 32. Spacer
13. Sliding quill gear 33. Countershaft front bearing
14. Sliding gear coupling 34. Retaining washer
15. Pilot bearing 35. Lockplate
16. Transmission driving shaft 36. Gasket
17. Circlip 37. Bearing retainer
18. Driving shaft bearing 38. Circlip
19. Circlip 39. Revere idler
20. Gasket 40. Reverse idler shaft and gear
Fig. 27 - Exploded View of Basic Transmission with Standard P.T.O.

they are firmly and squarely against the adjacent to 1st reverse gear.
shoulder of the cage. 4. Install 3.5mm. lug spacer beside the circlip
2. Press the rear bearing cone (2-27) onto the (11-33).
shaft with the large diameter end against the 5. Install bush in (12-33) 2nd gear (13-33) bore
pinion. and slide the assembly over the spline shaft
3. Slide the spacer (3-27), Shims (if fitted) and upto spacer keeping dog teeth of gear are
bearing cage onto the shaft and up to the rear toward the spline shaft pilot end.
bearing cone. 6. Install Hub (14-33) coupling on it.
4. Press the front bearing cone (6-27) onto the 7. Install bush (16-33) in 3rd gear (17-33) and
shaft and into the cage. then slide the assembly over splin shaft dog
5. Screw on the first locknut and tighten teeth of the gear toward hub.
securely, then install the lockwasher and 8. Install lug spacer (18-33).
second locknut and secure with a special 9. Install 4th & direct speed coupling (19-33) on
wrench MST-H1/2-TN-2 (fig-27a) the spline shaft step.
10. Install spacer and circlip (20,21-23).
11. Press 25.4mm needle roller bearing counter
bore side 19mm needle roller bearing other
side with a suitable mandrel in (23-33).
12. Install the quill gear assembly (23-33) on the
fig. 27a ground portion of spline shaft counter bore
6. Using suitable punch, bend the lockwasher facing towards 4th & direct speed coupling.
into the groove of both locknuts. Press the 13. Install gear sliding 4th speed (22-33) over quill
two needle roller bearings into the sliding quill splines with dog teeth towards 4th & direct
gear (13-27) using a suitable mandrel. speed coupling (19-33).
154 NOTE : Fig. 35 shows the type of mandrel required 14. Install high speed coupling (24-33) over quill
for removal and installation of needle roller splines with the dog teeth toward spline shaft
bearings. The bearing must be dipped in pilot.
Transmission oil before assembly and the NOTE : In this section sub-assembly of constant
mandrel pressed against the ends of the mesh transmission which is the same as
bearing. that of the sliding mesh transmission has
7. Install the first and reverse sliding gear not been described.
(9-27) with the fork groove away from the d. THE GEARBOX SHIFTER HOUSING
pinion end of the shaft. - SLIDING MESH
8. Install the second and third speed gear 1. Press the oil seal (3-34) into the cover with
coupling gear (10-27) with the fork groove the lip facing inwards.
towards the pinion. 2. Slide the hi-low shifter shaft through the oil
9. Install the fourth and direct speed coupling seal and thread on the two cams (20, 25-34)
gear (11-27), sliding quill gear (13-27) 4th and noting that cam (20-34) with the single lug is
direct sliding coupling (12-27) and sliding gear nearest to the oil seal.
coupling. The spline lead on the tear coupling 3. Position the cams and drive in roll pin.
(14-27) must face away from the pinion end 4. Insert the poppet spring and ball (3, 4-34) and
of the shaft. assemble the shifter handle (1-34) to the shaft
c. SPLINE SHAFT (CONSTANT MESH) and drive in the groove pin.
1. Spline shaft assembly and adjustment as per 5. Support the cover upside down on a bench
para 6c. 1 to 6. and fit the poppet springs (5-34) in their
2. Install 1st and reverse gear (9-33) on the bores and lay the balls (4-34) on top.
spline shaft with it’s fork collar toward pilot 6. Refer to illustration 34 and lay the shifter rails
side. and guides in position with the poppet balls
3. Install the outer circlip (10-33) in the groove engaged in the natural recess of each rail.

TRANSMISSION GEARS AND SHAFTS - PARTIAL CONSTANTMESH TRANS.
1st Version 3rd set.pmd

1. Splin shaft 24. Coupling high speed
2. Bearing 25. Bearing pilot
3. Spacer 26. Shaft drive
4. Shim 27. Circlip
5. Cage Trans Splin 28. Bearing
155
6. Bearing 29. Circlip
7. Nut 30. Gasket
8. Lockwasher 31. Cage Bearing
9. Gear sliding 1st & Rev. 32. Oil Seal
10. Circlip 33. Circlip
11. Spacer
12. Bush
13. Second speed constant
14. Hub
15. Ring control shifting
16. Bush third speed gear
17. 3rd speed constant mesh gear
18. Spacer
19. Spacer
20. Circlip
21. Coupling 4th & Direct
22. Gear coupling 4th & direct sliding
23. Gear quill sliding
6/3/2006, 11:18 AM
Fig. 33
155
156
Fig. 34
Exploded View of the Gear Shifter Mechanism & Transmission Case Cover - Sliding Mesh
1. Hi-Io range handle 17. Shifter housing

2. Shifter shaft 18. Gasket
3. Oil seal 19. Small pivot shaft
4. Poppet ball 20. Hi-low shifter cam
5. Poppet spring 21. Fork high speed shifter
6. Expansion plug 22. Guide L.H.
7. Gear shift lever ball 23. 4th speed shifter
8. Gear shift lever 24. Guides inner
9. Large pivot shaft 25. Low speed shifter cam
10. Plug 26. 2nd & 3rd shifter
11. Spring stop 27. 1st & reverse shifter
12. Spring 28. Bracket
13. Felt retainer 29. Lockplates
14. Felt washer 30. Guide R.H.
15. Washer 31. Low speed shifter
16. Shield 32. Bracket

Constant Mesh Gear Shifter Mechanism
Fig. 32
157

7. Install the brackets (28 & 32-34) using new Fitment of 4th Speed fork
bolt locks. Tighten the capscrews then turn 1. Insert spring and ball in adjacent to L.H.
the locks securely. extreme poppet hole.
8. Thread the shield, washer, felt, felt retainer, 2. Insert rail, coupling 4th speed and fork 4th
spring and spring stop (11-16-34) on to the speed (40, 39 & 41-32) in Trans-cover, so
shifter lever and secure with the cotter pin. that the coupling in the center of the rail and
9. Fit the large pivot shaft (9-34) in the lever with fork is on front (Engine) side.
the hole positioned at right angles to the lever 3. Press the ball, move the rail in position, and
centre line. lock coupling & fork by two roll pins.
10. Insert the lever into the housing and while Fitment of high speed rail
pressing down on the shield spring, insert the 1. Insert spring and ball in L.H. extreme hole.
small pivot shaft (19-34) through the cover 2. Insert rail & coupling (43 & 44-32) in trans-
and the hole in the large pivot shaft. cover.
11. Install the two expansion plugs (6-34) to 3. Press ball and move the rail in position & fix
retainer the small pivot shaft. high speed fork (42-32) and coupling by roll
e. THE GEAR SHIFTER HOUSING pins.
(CONSTANT MESH) 4. Place the retainer plate & lock plate
1. Install rubber boot (23-32) on t/c cover with (45 & 46-32) and bolt it.
help of 2 types of lock plates. 5. Insert oil seal high low range shifter shaft
2. Install high & low camshaft (2-32) with low (5-32) counter bore.
& high (4 & 3-32) on trans-cover. 6. Place the high low shifter on high low
camshaft after inserting spring & ball & lock
Fitment of low speed rail
by roll pin.
1. Insert the spring & then ball in the RH extreme
7. Fix expansion plug (9-32).
poppet hole of cover.
8. Press two dowel pins (48-32) on trans
2. Insert rail & coupling low speed (29 & 30-32)
housing cover front and place assembly of
158 in cover with the help of ball pressing unit. trans-cover front on housing cover with
Press ball & move the low speed rail in gasket.
position : fix low speed coupling by means
9. Bolt with 8 bolts.
of roll pin.
10. Fix the main gear shifter lever assembly &
Fitment of first & reverse rail & fork
seal swivel shaft hole with (8-32) on either
1. Insert the spring & ball in adjacent to R.H. side.
extreme popppet hole. 11. Fix oil filler plug.
2. Insert rail, coupling 1st & reverse & fork 1st 7. INSTALLATION
& reverse (33, 32 & 34-32) in trans-cover to
a. THE REVERSE IDLER
locate coupling Rail & fork in center towards
rear (lower link side) with the help of ball 1. Press the bronze bush, if removed, into the
pressing unit. Press the ball and move the lug bore of the transmission case.
rail (33-32) in position and mount coupling & 2. Remove the expansion plug for line reaming
fork (32 & 34-32) by two roll pins (35-32) in operation if a new bushing was installed.
position. 3. Install a new needle roller bearing.
3. Insert lock pin (36-32) 4. Install a new expansion plug using a good
Fitment of 2nd & 3rd speed fork sealing compound.
1. Insert spring and ball in middle hold (Trans- 5. Lubricate the bush & needle roller bearing with
cover). transmission oil and slide the reverse idler
shaft and gear (40-27) through the lug,
2. Press the ball and move the rail (37-32) in threading on the driving gear at the same
position, mount the fork (38-32) on rail and time. The driving gear rounded end teeth must
lock by roll pin. face the shaft gear.
3. Insert second lock inter lock pin by the help 6. From the differential compartment place the
of special tool. washer on the shaft and secure with the
circlip.

7. Replace the R-H-bull gear as detailed in gasket.

“AXLE & WHEELS”. 3. Lever down on the counter shaft and at the same
b. THE TRANSMISSION COUNTER SHAFT time slide the driving shaft home. The countershaft
1. Place the counter shaft, complete with gears into must be levered down to permit the teeth of the
the transmission case. high range dog to clear helical constantmesh gear
of the counter shaft.
2. Slide the spacer (32-27) on to the shaft with the
deep chamfer toward the constant mesh gear. NOTE : To facilitate removel of driving shaft with out
removing countershaft bearing. The dogteeth
3. Install the front bearing using the special tool.
have been shaven on new models.
NOTE : This will centralise the shaft in the rear bearing
4. Insert and fighten the four driving shaft bearing
bore.
cage retaining capscrews. (3-19)
4. WITH THE STANDARD P.T.O. 5. Install the countershaft spacer (32-27) retainer
a. Assemble the retaining washer (34-27) using washer, lockplate and two capscrews if it was
a new lock plate. removed and torque.
b. Tighter the two capscrews but do not turn up NOTE : Ensure there is slight end float (0.127mm -
lock plate. 0.254mm) on the constantmesh gear, if there
c. Assemble the bearing retainer (37-27) using is too much end float, drive the countershaft
a new gasket, and tighten the four caps forward with a drift and retighten the retaining
crews. capscrews. If there is insufficient end float,
5. WITH C.R.P.T.O. suspect faulty parts or incorrect assembly of
counter shaft gears to the shaft.
a. Place the lock washer with the tag located
in the slot of the shaft. 6. Replace the bearing retainer and secure with four
capscrews (2-19)
b. Screw on and tighten the retaining nut
(4-23) but do not turn up the lock washer. e. THE TRANSMISSION DRIVING SHAFT
C.R.P.T.O
c. Assemble the bearing retainer (2-23) and
tighten the four capscrews. 1. Remove the counter shaft retainer locknut and 159
lockwasher then pull the bearing and spacer off
6. Drive the counter shaft rear bearing (25-27) on to
the counter shaft.
the shaft and into the bore and scure with the
circlip. 2. Complete ops. 2 to 4 para 7d.
NOTE : With the standard P.T.O. take care not to 3. Install the spacer, bearing lockwasher and retainer
damage the counter shaft spigot when nut.
replacing the rear bearing. NOTE : To facilitate removel of driving shaft with out
c. THE SPLINE SHAFT removing countershaft bearing, the dogteeth
have been shaven on new models.
1. Determine the correct thickness of shims to
give the required pinion cone centre distance 4. Securely lock the retainer nut and replace the
as detailed in the DIFFERENTIAL section of bearing retainer and secure with four screws.
this manual. f. THE GEARBOX SHIFTER HOUSING
2. Install the spline shaft assembly into the 1. Place a new gasket on the transmission case.
transmission case with the bearing cage 2. Position the sliding gears in neutral and the shifter
located on the three bolts and the necessary rails in neutral.
shim thickness in position. 3. Lower the shifter mechanism onto the transmission
3. Screw on and tighten, the three retaining nuts case engaging the shifter forks in their respective
to the correct torque (see SPECIFICATIONS). slots.
d. THE TRANSMISSION DRIVING SHAFT 4. Insert and tighten the eight retaining capscrews.
(Standard P.T.O) g. ASSEMBLING THE TRACTOR
1. Remove the counter shaft bearing retainer, 1. Assemble the differential, axles and brakes, if
capscrews and washer then pull the bearing and these were removed, and check the bevel gear
spacer off the counter shaft. backlash.
2. Install the driving shaft and bearing cage assembly 2. Assemble the front of the tractor to the
into the transmission case bore using a new transmission case taking care, in the case of the

Constant Running P.T.O. that the driving shaft is Therefore :-

centralised in the hollow P.T.O. driving shaft and Amount of end float to be removed is
that the oil seal is not damaged. 0.18mm + 0.13mm = 0.31mm
In both types, the driving shaft must be turned Standard spacer measures .... .6.22mm
to engage the clutch plate splines and care must Therefore :
be taken when entering the shaft spigot into the Thickness of spacer and shims to be installed is
pilot bearing. 6.22mm - 0.30mm = 5.92mm
Insert and tighten the capscrews. NOTE : The average thickness of the spacer is
3. Assemble the P.T.O. as described in POWER 4.7mm and shims are available in thickness
TAKE-OFF for the type of P.T.O. fitted. of 0.05mm, 0.10mm and 0.25mm.
4. Install the hydraulic lift as described in the 6. Remove the locknut and press the shaft and rear
HYDRAULICS section. bearing cone from the cage and front bearing
5. Install the left hand footplate capscrew and cone.
connect up the electrical wiring. 7. Remove the standard spacer from the shaft then
6. Fill the transmission and Hydraulic system with install the correct thickness spacer.
the correct grade lubricant for prevailing 8. Assemble the cage, front bearing cane, locknuts,
temperature. lockwashers and sliding gears as detailed in para.
h. ADJUSTMENTS 6c.
Adjusting the spline shaft bearing pre-load i. THE PINION CONE CENTRE DISTANCE
1. Using a standard spacer measuring 6.22mm on 1. The correct centre distance is elched on the
the machined flat surfaces, assemble the shaft machined face of the pinion. Also etched on this
and bearings into the cage as detailed in para. face is the set number of the pinion and bevel
7c ops. I to 5 and secure with one locknut. gear. Ensure that the pinion and bevel gear are
matched.
2. Install the spline shaft into the transmission case
and tighten the three retaining nuts to the NOTE : Spline shaft mounting distance is directly
160
specified torque. etched on the bevel gear machined face as
16.15mm or any.
NOTE : If the differential is in position, sufficient shim
thickness must be installed to ensure that the 2. Install the spline shaft using a shim pack of
end float of the spline shaft is not restricted 2.28mm between the bearing cage and the
by the bevel gear. If the differential is not in Transmission case Tighten the retainer capscrews
position, no shim should be used. to the correct torque.
3. Install a dial indicator on the transmissions case 3. Using parallel gauge block special service tool
with the stylus bearing against the machined face MST-H1/2-TN-3 (fig. 33 & 34) measure the
of the pinion. distance between the bevel pinion machined face
and the machined O.D. of the L.H. differential
4. Determine the end float of the spline shaft by
case.
pushing the spline shaft firmly to the rear and
noting the reading, then pulling the shaft forward
and noting the reading.
NOTE (1) : Several measurements should be taken,
rotating the shaft at each reading.
Fig. 33
(2) : Ensure that the extreme length of travel
is reached in each direction.
5. As the pre-load on the spline shaft rear bearings
is the equivalent of 0.13mm tight, the thickness
of spacer and shims is determined as in the
following example.
End float measured ................. .0.18mm
Fixed pre-load ......................... .0.13mm
Fig. 34

EXAMPLE : If spline shaft mounting distance is bull pinion bearing cage and vice versa.
directly etched as 1.61mm and thickness A 0.12mm shim transfer approximates to a
of parallel gauge block is 15.95mm then reduction or increase of 0.08mm backlash.
feeler gauge of 0.20mm should go. If it
is going very easily then measure the
looseness, if the feeler gauge of 0.3mm
is going instead of 0.2mm, it means
distance between spline shaft and
transmission case is more by 0.1mm
Therefore 0.1mm of shims must be
removed.
Similarly if the feeler gauge of 0.1mm is
going instead of 0.2mm then add the
shims 0.1mm to increase the distance.
NOTE : Measurements should be made every 900 and
the average of these readings should be
taken.
4. With the correct shim pack assemble the
bevel pinion with the gears and quill shaft.
5. Re check the mounting distance.
CAUTION : During the cone center adjustment

it is imperative that backlash be present
j. BACKLASH ADJUSTMENT
The blacklash for a given pair of splined shaft
(pinion gear) and bevel (ring on crown) gear
161
is determined at the factory and is etched on
the outer surface of the bevel gear. Adjust
backlash to the etched number ± 0.05 mm,
preferable toward the lower limit.
NOTE : The backlash is adjusted by removing shims
from one bull pinion bearing cage and fitting
them to other side. The same quantity of
shims must be maintained at all time as
otherwise the “PRE-LOAD” of the tapered
roller bearing will be upset.
1. Rigidly mount a dial indicator against a gear
tooth, being sure that indicator system is
perpendicular to the tooth surface at the
extreme heels.
2. Engage two sliding gears in mesh this will
hold the pinion quite still but a pinch bar used
as a lever against one of the teeth of the
sliding will ensure complete rigidity.
3. Rock the bevel gear noting total indicator
reading.
4. Repeat measurement every 900 of the bevel
gear.
5. Excessive backlash is reduced by removing
shims from the right hand bull pinion bearing
cage and assembling them to the left hand

8. TROUBLE SHOOTING
PROBABLE CAUSE PROBABLE REMEDY

GEARS HARD TO SHIFT
Oil in transmission too heavy ............................................... Drain and fill with recommended grade.
Gear shifter forks and/or rails out of
alignment or damaged .................................................... Inspect forks and rails. If bent or damaged replace.
Worn shifting controls ............................................................ Repair or replace.
Damaged transmission parts ................................................. Inspect transmission and replace damaged parts.
GEARS CLASH
Engine clutch not releasing properly, or
dragging Refer to ENGINE CLUTCH section of this manual.
Damaged transmission parts ................................................. Inspect transmission and replace damaged parts.
GEARS NOT FULLY MESHING
Shifter forks and/or rails worn excessively .......................... Replace with new parts.
Shifter forks and/or rails bent ................................................ Replace or repair.
Worn or broken bearings ........................................................ Replace.
GEARS SLIP OUT OF MESH
Gears not fully engaged ......................................................... Inspect shift rails and forks, Check their travel.
Damaged transmission parts ................................................. Replace as necessary.
Shifter forks and poppets not properly
162 assembled or weak poppet springs ............................... Inspect assembly. Replace weak or broken poppet
springs and balls.
NOISY TRANSMISSION
Bearings worn or broken ........................................................ Replace.
Pinion shaft worn ................................................................... Replace pinion shaft and ring gear.
Gears badly worn ................................................................... Replace.
Bevel gear and pinion not correctly adjusted ....................... Check and adjust to correct clearance and back
lash. (Refer to DIFFERENTIAL section of this manual.
Para. 9 ADJUSTMENTS).
Broken or damaged transmission case ................................ Inspect rear frame for breaks or damage.
Repair or replace as required.
GEARS DO NOT SHIFT
Engine clutch drags ............................................................... Refer to ENGINE CLUTCH section of this manual.
Gears stuck on spline shaft .................................................. Remove spline shaft and check for burrs or scores.
Check freedom of gear movement on spline. If
excessively worn replace gear and shaft.
Shifter forks and poppets not properly
assembled or broken poppet springs ............................. Inspect shifter mechanism. Replace damaged parts.
LUBRICANT LEAKAGE
Lubricant deals past transmission drive shaft oil
seal, or bearing cage gasket .......................................... Replace oil seal and gasket.

Transmission - Differential
Chapter-2 Differential
Specification
Description
Differential Removal & Dismantling
Assembly, Installation & Adjustments
Trouble Shooting
163

Transmission - Differential (Chart)
164

1. SPECIFICATIONS
Differential Bevel Gears. No. used 2

Differential Bevel Gears, No. of teeth 24
Differential Bevel Pinion. No. used 4
Differential Bevel Pinion. No. of teeth 13
Spider Shaft - Diameter 25.4mm - 25.43mm
Differential Case Bearings, type Taper - Roller
Differential Case Bearings, Pre-loaded 0.5 Nm - 1.69 Nm
Bull Pinion Shaft Bearings, type Ball
Drive Bevel (Ring or Crown) Gear, No. of teeth 44
Drive Bevel Gear Backlash As stamped on Gear
Differential Lock Clutch, O.D. 63.5mm
Differential Lock Clutch, Major Diameter 35.53mm - 35.63mm
Differential Lock Clutch, Minor Diameter 44.40mm - 44.50mm
Differential Lock Shaft - Length 304.8mm
Differential Lock Spring, No. used 2
Differential Lock Spring Free Length 92.07mm
Differential Lock Spring Max. Length in use 71.44mm
Differential Lock Spring, Min Length in use 54.76mm
Differential Lock Spring, Max. Solid Height 52.38mm
Differential Lock Spring, Test Length 53.98mm
Differential Lock Spring, Test Load 24.86 kg
Differential Lock Spring, Total No. of Coils 19.75 165
Differential Lock Spring, Total No of Working Coils 18
Differential Lock Spring, O.D. 18.77mm
Differential Lock Spring, l.D. 13.48mm
Differential Lock Spring, Wire Diameter 2.64mm
Torque Loading
Driving Bevel Gear Retaining Bolt 105 Nm - 119 Nm
Ball Pinion Cage Bolts 95 Nm - 101 Nm
Ball Pinion Cage Roll Pin 67 Nm - 85 Nm
2. DESCRIPTION
a. The differential is located in the rear frame and drive pinion and bevel gear tooth contact is
is mounted on two taper roller bearings. The drive obtained by shims between the transmission
bevel (ring or crown) gear is bolted to the splined shaft roller bearing retainer and the
differential case. machined surface of the gear box.
The outer ends of the bull pinion shafts are Incorporated and running through the right hand
mounted on ball bearings carried in cages bull pinion shaft is a differential lock unit which
assembled on the rear frame. Mounted on the is controlled by a foot pedal assembled to the
shafts are disc brakes. right hand disc brake housing.
Shims, located between the differential bearing The differential lock when engaged, connects the
cages and sides of the rear frame, determine the two bull pinion shaft, thus making if impossible
backlash between the bevel gear and drive pinion for the rear wheels to turn at different speeds. It
and the pre-load on the taper roller bearings is used to help overcome wheel slippage.
support that the differential. Adjustment of the

3. REMOVAL b. The Differential Lock

a. Preliminary
1. Insert wooden wedges between the axle and
axle support, to prevent the tractor rolling
about the front axle pivot pin, and chock the
front wheels.
2. Jack up the rear end and support securely
on blocks positioned under the main frame.
CAUTION : Ensure that the tractor is
adequately supported before proceeding to remove the
rear wheels.
3. Drain oil from the transmission and hydraulic
lift housing.
4. Disconnect the rear lighting leads. Fig. 2
5. Remove the wheels and fenders. 1. Turn the left hand bull pinion shaft until the
6. Remove the hydraulic lift housing as detailed differential lock splines are out of alignment
in “HYDRAULICS” in this manual. then press in the "O" ring retainer (1-2)
exposing the operating rod circlip (1-3).
7. Remove the brakes as detailed in "BRAKES"
2. Remove the circlip (1 -3) fro in the groove
8. Remove the axle and axle housings as (5-3) in the operating rod (6-3) then draw out
detailed in “AXLES” the "O" ring retainer (2-3) and the outer spring
9. Remove the P.T.O. shaft. (4-3).
166
Fig. 3
c. The Bull Pinion Shaft Bearing Cage
1. Remove the five retaining capscrews (2-2)
and one roll pin bolt (5-2), then draw out each
bearing cage (3-2), Remove the roll pins from
the main frame only if inspection reveals
damage.
NOTE (1) : Care must be taken that the differential
assembly is not allowed to drop when
the bearing cages are removed.
Fig. 1 NOTE (2) : The brake housing attaching bolt holes
(4-2) in the bearing cage may be used
10. Lift the bull gears (1-1) from the transmission as puller holes but the use of puller bolts
case after marking the gears to ensure will damage the shims (1-4) which will
reassembly in their original locations. have to be replaced.

Shims
Fig. 6
Fig. 4
167
Fig. 5
2. Lift the differential complete with differential

lock from the transmission (see Fig. 5).
4. DISMANTLING
a. The Bull Pinion Shaft Bearing Cage Fig. 8
1. Remove the shim pack (6-6) from each cage
(4-6), then tape together if not damaged, until
required for installation.
2. Press the bull pinion shaft out of the cage
through the differential end of the cage (see
Fig. 6).
CAUTION : If the Roller bearing (3-6) comes out

with the shaft (2-6), care must be taken when the
bearing comes into contact with the inner bearing cup
(1-6).
If the ball bearing remains in the housing, remove
the ball bearing (3-6) and inner bearing cup
(1-6).
3. Remove the oil seal (5-6). Fig. 9

Fig. 12
Fig. 10
b. The Differential
1. Mark each half of the differential case so that
they can be reassembled in their original
position.
2. Turn down the lockpiate corners (1-8) and
remove the eight capscrews (2-8).
3. Lift off the left hand differential case (3-8).
4. Remove the left hand differential bevel gear
(1-9), then the differential lock clutch
assembly (2-9), (see Fig. 10).
168
Fig. 13
(3-12), drive the bearing cones (4-8 & 2-13)

from the case halves.
NOTE : Care must be taken to drive the bearing
cones off evenly using the three holes in turn.
c. The Differential Lock
1. Tap Out the dowel pin (4-14) from the
differential lockshaft (5-14) and collar, then
slide the collar (7-14) and inner spring
(6-14) from the shaft.
Fig. 11 2. Tap out the groove pin (1-14) and remove the
differential lock clutch (2-14) and spacer (3-
5. The differential pinion shafts are pinned into 14) from the shaft.
the right hand casing (4-9), and can be 3. Remove the inner and outer “O” rings (9 &
removed by driving upwards against the 11-14) from the “O” ring retainer (8-14).
chamfered edge of the shaft using a soft 5. CLEANING, INSPECTION & REPAIR
copper drift (see Fig. 11).
1. Clean all parts in a suitable solvent and blow dry
6. Remove the right hand bevel gear (1-12) from with compressed air. Be careful not to remove the
the case. identification marks from the differential case
7. Remove the twelve capscrews (1-13) halves.
attaching the drive bevel gear (2-12) to the 2. Inspect all bearings for cracks, chipping or signs
right hand differential case. of wear and check that they rotate freely. Lubricate
8. Using a suitable drift in the three holes the bearings and wrap in grease proof paper until
provided in each half of the differential case required for reassembly.

1. Bull pinion shaft L.H. -
Bearing cage
2. Bull pinion shaft bearing
cage shim
3. Bull pinion shaft oil seal
4. Bull pinion shaft roller/
ball bearing
5. Bull pinion and brake
shaft - L.H.
6. Differential tapper roller
15
bearing
7. Lock plate
8. Differential case
9. Differential bevel
(Ring or Crown) gear
10. Differential shaft
11. Differential pinion
12. Drive bevel gear
13. Bull pinion and brake
shaft R.H.
14. Bull pinion shaft
Fig. 7 - Exploded View of Differential R.H. - bearing cage
15. Differential case
169
1. Pin
2. Differential lock clutch
3. Spacer
4. Pin
5. Differential lock shaft
6. Spring
7. Collar
8. “O” ring retainer
9. Inner “O”ring
10. Oil seal
11. Outer “O”ring
12. Circlip
13. Lever
14. Thrust plate
15. Bolt
16. Spring
17. Return spring anchor plate
Fig. 14 - Differential Lock

3. Inspect all gears for chipped, cracked or badly 6. Install the four lockplates and eight
pitted teeth. capscrews and secure by turning up the
4. Inspect bearing cages for damage. lockplate corners.
5. Check the bull pinion shafts for scoring or wear d. The Bull Pinion Shaft Bearing Cage
on the splines. 1. Press the oil seal (5-6) into the bearing cage
6. Inspect the four pinion shafts and pinion bores (4-6) with the lip facing inwards.
for wear. Refer to “SPECIFICATIONS” for 2. Press the bull pinion bearing (3-6) onto the
dimensional clearances. shaft (2-6) then press the shaft into the
7. Replace any parts found to be worn or faulty. bearing cage.
6. ASSEMBLY NOTE : Extreme care should be taken when carrying
out op. 2 to ensure the oil seal (5-6) is not
a. General
damaged.
1. Use new gaskets, “0” rings oil seals and bolt
3. Press the differential cup (1-6) into the cage.
lockplates for reassembly of the differential.
7. INSTALLATION
2. Ensure that all bearings are clean and
lubricated when assembled. a. The Differential and Bull Pinions
3. Lubricate all moving parts with the specified 1. Install the roll pins in the main frame, if
oil before assembly to ensure starting removed, then slide the L. H. bull pinion and
lubrication. bearing cage with shims in position and
secure with two capscrews placed
b. The Differential Lock
diametrically opposite each other.
1. Install new “O” rings (9 & 11-14) in the
2. Slide the left hand bull pinion and bearing
internal and external grooves of the “O” ring
cage with the shims in position and secure
retainer (8-14).
with two capscrews placed diametrically
2. Assemble the spacer (3-14) and lock clutch opposite each other.
(2-14) to the shaft (5-14) and drive in the
170 NOTE: If the bevel gear shims have been replaced,
groove pin (1-14).
install shims of equal thickness to those
3. Slide the inner spring (6-14) onto the shaft removed on dismantling.
then install the collar (7-14) and secure with
3. Engage the differential lock clutch on the
pin (4-14).
splines of the left hand bull pinion shaft.
4. The other component parts of the differential
4. Slide the right hand bull pinion and bearing
lock will be assembled during installation.
cage with the shims in position making sure
c. The Differential the slot in the end of the bull pinion shaft is
1. Press the bearing cones onto the spigots of aligned with the groove pin retaining the
the differential case halves. differential lock clutch.
2. Attach the bevel drive gear (12-7) to the right NOTE: If the slot and pin are not correctly aligned,
hand differential cage (15-7) by means of the the bearing cage cannot be pushed home.
twelve capscrews, then torque to the specified 5. Insert two retaining capscrews diametrically
figure. Refer to “SPECIFICATIONS” para. 2. opposite each other.
Torque Loadings.
6. Pre-load the bearings before adjusting the
3. Lay the right hand bevel gear (9-7) in the backlash as detailed in “ADJUSTMENTS”.
case then assemble the four differential
7. Adjust the shimming to give the correct drive
pinions (11-7) to their shafts (10-7) and tap
bevel gear backlash as detailed in
the pins into the holes in the case.
“ADJUSTMENTS”.
4. Install the differential lock assembly (see Fig.
NOTE : If the differential assembly is to be set after
10), then place the left hand bevel gear
transmission assembly, the correct pinion
(9-7) on the pinions.
cone centre distance must be established
5. Place the left hand differential case (8-7) in before setting the bevel gear backlash.
position, aligning the marks made before
8. Install the remaining three bearing cage
dismantling.

capscrews and one roll pin bolt, then torque (3) Pre-load the bevel pinion bearings. This is
to the specified figure. Refer to described in the ‘Transmission’ section of this
“SPECIFICATIONS” Para 2 Torque Loadings. manual.
9. Installation of the remaining differential lock (4) Cone centre (mounting distance) adjustment.
components can now be completed as follows: (5) Back lash adjustment.
(a) Pull the operating shall out until the clutch MATCHED SET
is disengaged, then turn so that the clutch
As previously mentioned the bevel gear and pinion are
splines bear against the left hand shaft
furnished as matched sets. The first operation is to
splines.
ensure that the selected set are in fact a matched set.
(b) Slide the outer differential lock spring (4-3)
onto the differential shaft and into the bull
pinion shaft bore.
(c) Smear the differential lockshaft, retainer “O”
rings with a little oil, grease or soap solution
and slide the retainer (2-3) onto the differential
lockshaft (6-3).
(d) Press in the “O” ring retainer until the circlip
groove (5-3) is exposed and install the circlip
(1-3).
10. Install the bull gears and axles as detailed in
“AXLES”
11. Install and adjust the brakes as detailed in
“BRAKES”
12. Replace the rear P.T.O. shaft as detailed in
“POWER TAKE-OFF” 171
13. Install the hydraulic lift housing as detailed in
“HYDRAULICS”
14. Install the tenders and connect up the light cables.
15. Assemble the differential lock lever and
thrustplate, adjusting clearances as detailed in
“ADJUSTMENTS”.
Fig. 15
16. Fill the transmission and hydraulic housing with
the specified oil.
b. Pre-Loading The Bevel Gear Bearings With
8. ADJUSTMENTS The Bevel Pinion And Bull Pinion Shafts Out.
a. General 1. Install the differential and bull pinions as
The bevel gear and pinion are serviced in detailed in para. 8a ops.1 to 5 using 12.7mm
matched sets and should only be fitted as such. - 1.42mm shim packs between the bearing
In order to eliminate the tedious process of cages and main frame.
setting a bevel gear and pinion with marking ink 2. Loop both ends of a piece of string and slip
the serviceman is provided with certain information one loop round a differential bolt head. Then
relative to that particular set. wind the string around the differential housing,
In order to ensure quiet operation and long life of secure a spring balance into the free end (as
the bevel gear and pinion the following assembly shown in Fig. 15) and pull.
and adjustment procedure should be rightly NOTE : The pull is that required to keep the
followed. assembly revolving at a constant speed and
(1) Check the pinion and gear are a matched set. should be between 2.7kg - 4.5kg/pull, if the
(Number) original bull pinion and brake shaft oil seals
(2) Pre-load the bevel gear bearings. are reused, the pull should be made 1.3 kg/
2.3 kg

3. Add or remove shims between the right hand pinion which has been set too far out. This tends
bearing cage and the main frame until the~ to cause premature wear of the bevel gear.
above figure is obtained. If it is necessary to reset the pinion the backlash
4. Once the correct pre-load has been obtained will need to be adjusted (see para. 8(f)).
it will only be necessary to transfer shims (i) The Differential Lock
from one bearing cage to another to obtain
1. The differential lock lever must be clear of the
the correct backlash.
end of the differential lock shaft by 0.8mm -
c. Pre-Loading The Bevel Gear Bearings With 1.58mm when assembled and in the disengaged
The Transmission Assembled. position. This clearance is obtained by washers
1. This method should be used when servicing (e.g. on the pivot bolt.
bearing change) has been carried out on the 2. The lock lever thrust plate must support, but not
differential assembly without dismantling the displace, the lock lever. This is achieved by
transmission. means of the washers on the thrust plate (Refer
(a) Remove the bevel gear from the differential to Fig. 17).
case.
(b) Install the differential assembly as detailed
in para 9b and adjust the shims to give the
correct pre-load.
(c) Remove the differential assembly, then
reassemble using same shim thickness as
determined in (b) above.
d. Pre-Loading The Bevel Pinion Bearings
1. This is fully described in ‘ADJUSTMENTS’ of the
‘TRANSMISSION’
172 e. Adjustment of the Cone Centre Depth
This is fully described in ‘ADJUSTMENTS’ of the
Transmission. Refer para 7h.
f. Backlash Adjustment
This is fully described in ‘ADJUSTMENTS’ of the
Transmission. Refer pare 7j.
g. Checking Tooth Bearing Contact
The adjustment of the bevel gear and pinion can
be finally checked by painting the pinion teeth Fig. 17 - Differential Lock Adjustment Washers
profiles with some suitable marking medium and
rotating the bevel gear against the pinion in both
forward and backward directions.
If the setting is correct the marking will be
transferred to the bevel gear teeth as shown in
illusts. 18 and 19. These checks should be taken
at 90 intervals on the bevel gear. When correctly
set the tooth bearing is central and under load the
contact will extend from the toe towards the heel
of the tooth. This will allow the gears to operate
quietly.
Illustrations 20 and 21 show the markings of a
pinion which has been set too far in. This gives
incorrect tooth contact resulting in noisy operation
and premature wear of the pinion.
Illustrations 22 and 23 show the markings of a

Fig. 18 Fig. 19
173
Fig. 20 Fig. 21
Fig. 22 Fig. 23

9. TROUBLE SHOOTING
A. Tractor does not move. (1) Engine Clutch Faulty (1) Refer to ‘Engine Clutch’
Section
(2) Transmission Faulty (2) Refer to 'Transmission'
Section
(3) Rear Axle Faulty (3) Refer to 'Axles' Section
(4) Differential Faulty (4) Remove Differential,
disassemble and inspect
B. Tractor moves but at (1) Engine Clutch Slips (1) Refer to 'Engine Clutch'
reduced speed Section
(2) Binding in Transmission (2) Refer to 'Transmission'
Section
(3) Binding in Differential (3) Remove, disassemble
and inspect.
(4) Binding in Rear Axle (4) Refer to 'Axles' Section
(5) Binding in Front Wheels (5) Refer to 'Wheels' Section
C. Tractor will not turn (1) Steering Mechanism (1) Refer to 'Steering
174
Faulty Mechanism' Section
(2) Brake Pedals Interlocked (2) Release Pedal Lock
(3) Differential Faulty (3) Remove, disassemble
and inspect
D. Tractor moves but turns (1) Brake Dragging on one (1) Adjust Brakes
to one side. side
(2) Front Wheel Faulty (2) Refer to 'Wheels' Section
(3) Steering Mechanism (3) Refer to 'Steering
Faulty Mechanism' Section
(4) Binding in Differential (4) Remove, Disassemble
and inspect
(5) Uneven Tyre Inflation (5) Check Tyre Pressure
Pressure

Transmission - Power Take-offs Standard & C.R.P.T.O.
Chapter-3 Power Take-offs Standard & C.R.P.T.O.

Specification
Description
Removal, Cleaning, Inspection & Repair
Assembly & Adjustment
175

CRPTO
1. SPECIFICATIONS in mm
1. O.D. of counter shaft at bearing outer 90
2. O.D. of counter shaft at bearing inner 80
3. I.D. driven gear teeth (61) 16
4. P.T.O. shaft front O.D. for roller bearing 30 / 29.70
5. Main drive shaft oil seal dia. O.D. 54.91 x 100
6. Hollow shaft rear bearing O.D.
7. Hollow shaft oil seal O.D. 55.04 / 73.05
TORQUE NEWTON METER
1. P.T.O. mounting bolt 33.89 - 40.67

2. P.T.O. Cap 13.55 - 20.33
176

177
4
8
22
13
1. Clutch Housing 11. Oil seal Hollow shaft 21. Bolt

2. Bearing clutch Housing 12. Bolt washer Retainer brg 22. Bolt
3. Fork clutch Release 13. Cover clutch Hsg. Hand hole 23. Oil pan clutch Housing
4. Clip 14. Gasket 24. Drain plug
5. Shaft clutch Release 15. Circlip 25. Gear Driven P.T.O.
6. Bolt 16. Ball bearing, Hollow Drive shaft 26. Spacer P.T.O Shaft front
7. Flexible pipe 17. Hollow Drive shaft 27. Roller bearing P.T.O Shaft front
8. Gasket Handhole cover 18. Ball bearing H.O.Shaft 28. Circlip
9. Bolt 19. Shaft P.T.O Front 29. Gasket end
10. Bearing Retainer Hollow shaft 20. Gasket oil pan clutch Housing 30. End cover
Fig. 1
CRPTO CLUTCH HOUSING SUB-ASSY.

2. DESCRIPTION b. THE C.R.P.T.O. (SINGLE SPEED)

a. The P.T.O. shaft affords the means where by the In this version, a dual plate engine clutch is used.
tractor engine may be used to provide power to The P.T.O. drive shaft is hollow and runs out side
operate mounted, trailed or remote equipment. the transmission driving shaft. The front of the
The shaft is splined to received either the drive P.T.O. drive shaft is splined to the rear plate of
shaft for mounted or trailed equipment or the belt the engine clutch, while the shaft itself carries a
pulley to operate belt powered equipment. gear of the front P.T.O. shaft.
1. Constant Running The front P.T.O. shaft runs through the hollow
transmission shaft and at the rear end, has a
When the tractor is equipped with a standard
spigot to support the rear power take off shaft and
P.T.O. the out put shaft is driven by a solid
splines by which the P.T.O. clutch may engage
transmission counter shaft and when it is
the two shafts.
with constant running P.T.O., the P.T.O.
driving shaft and transmission counter shaft The P.T.O. clutch is as detailed in para1b. The
are both hollow. engine clutch has two friction plates. The rear
plate is splined to the PTO drive shaft. The clutch
With the constant Running version, either
control pedal may be depressed half way to stop
single or two speed, there is no lock-out and
the power take-off may be operated with either tractor movement while the PTO continues to run
high or low gear. or depressed fully, stopping both tractor and PTO
movement.
1. Clutch Shifter lever

2. Oil Seal
3. Shifter Bracket
4. Gasket
178 5. Shifter
6. Sliding clutch
7. Circlip
8. Bush
9. P.T.O Shaft
10. Gasket
11. Bearing
12. Oil seal
13. Spacer P.T.C Shaft Bearing
14. Oil Seal retainer
15. Cap Safety
16. Bolt
17. Bolt
18. Coller
Fig. 2
Exploded view of the rear P.T.O. extension shaft and shifter assy.

1. Clutch Housing
2. Shaft Clutch Release
3. Key Clutch Lever
4. Circlip Clutch Release Shaft
5. Fork Clutch Release
6. Nipple Grease
7. Bolt Clutch Release Fork 5/16”
8. Key Clutch Lever
9. Bearing Antifriction Clutch Release
10. Clutch Release Sleeve
11. Insert
12. Pipe Greasing
13. Clutch Pedal Assy.
14. Bracket Clutch pedal Mounting
15. Gasket Hand Hole Cover
16. Plate Hand Hole Cover
17. Gasket Clutch Housing to Transmission
18. Connecting link Clutch Pedal
19. Gasket, Oil Pan
20. Oil Pan
21. Magnetic Drain plug
22. Stud
23. Spring Clutch pedal
24. Gasket
25. Clutch housing mounting bolt
179
Fig. 3 Clutch Housing & Connections
3. REMOVAL
a. Rear P.T.O Extension Shaft & Shifter Assembly 2. Remove the clutch housing from the transmission
Standard and C.R.P.T.O. as detailed “TRANSMISSION” Groups.
1. Drain the oil from the transmission case. 3. Remove steering wheel and Seal steering column
2. Remove the rear P.T.O Safety shield, Safety cap 4. Remove the Instrument cluster and disconnect (2
or belt pulley (if fitted) cupperlers) from central harness.
3. Remove the Left hand foot plate, foot panel and 5. Remove the Instrument bezel sub. assembly from
foot step then move the shifter to the disengaged the scuttle hand accelerator lever by
Position to ensure that the Sliding clutch (6-2) is disconnecting accelerator cable from lever and
located on the shaft (9-2) Remove the three bolts Remove nylock nut spring governor control,
securing capscrews and with draw the shifter washers sunk screw.
assembly from the transmission housing. 6. Remove scuttle door from bracket assembly Rear
4. Remove the six bolts securing oil seal retainer attachment.
(14-2) and with draw the P.T.O shaft (9-2) 7. Remove the knob and nut from the pull to stop
complete with oil seal (12-2) Retainer (14-2) cable and pull out cable from the scuttle.
Spacer (13-2) two Bearings (11-2) and sliding
8. Disconnect the fuse box mounting bracket and
clutch (6-2). To remove P.T.O Shaft assembly
tie-up wiring harness.
clear of the transmission case
9. Remove scuttle assembly from fuel tank
b. The clutch Housing
mounting bracket.
1. Remove the engine from the clutch housing. As
10. Remove fuel tank assembly with fuel tank
detailed in “ENGINE CLUTCH”.
mounting bracket. Which is bolted on clutch
housing.

NOTE : Disconnect electrical wire fuel tank unit and 3. Slide the coupling (6-2) shaft (9-2) and remove
wiring harness clips from the scuttle circlip (7-2) and bush (8-2) if Inspection proves
assembly, before removing from the clutch this is necessary.
housing. 4. Remove the oil seal retainer (14-2) complete with
11. Remove bracket assy. Rear attachment mounted oil seal and gasket, then Remove the oil seal
on clutch housing. (12-2).
12. Remove steering unit Hydraulic four pipes, from 5. If necessary press off bearing (11-2) with spacer
the unit and Remove three bolts and one stud nut (13-2).
of steering box mounting from clutch housing. b. RELEASE BEARING MECHANISM.
Refer detailed in ‘Powersteering’ group
1 Loosen the pinch bolts (1-4) From the clutch pedal
connecting link Bracket.
CAUTION : Tag the pipes T for T and P for P 2. Remove the flexible pipe, flexible pipe clips (4-
like that as per marking on steering unit and install 1) and coupling nut (7-1).
the same as per marking. DO NOT interchange.
3. Remove the pinch bolts (3-4) and Key clutch
13. Disconnect the clutch pedal connecting link. lever from the clutch release fork (4-4). Then
14. Remove foot step attached to floor panel Front clutch shaft from the pedal. Side and out through
L.H. and clutch housing and remove bolts of fool the right side of the housing.
panel. L.H. by removing attaching bolts with pain 4. As the shaft slides out, the release bearing
and spring washers. assembly can be remove from the transmission.
15. Disconnect foot accelerator pin end from pedal 5. To Remove the release bearing sleeve which is
bracket and remove bracket and foot accelerator freely sliding over Hollow shaft Housing. Remove
pedal. From R.H. floor panel./ foot plate. Then two pins which are held by release fork and slide
remove the floor panel front R.H. by removing it off the P.T.O hollow shaft Housing.
bolts attached to clutch housing and nut bolt from c. ANTI FRICTION RELEASE BEARING
floor panel rear R.H.
180 1. An antifriction thrust bearing is fitted over a hollow
16. Remove Hose Suction pipe V.T.U to filter and
Hose suction filter to pump by Loosening hose
clips. Then remove three bolts of filter mounting
bracket.
NOTE : Plug and cap the oil pipes and filter ends to
prevent entering dust and dirt.
17. Check and secure wooden block or Suitable

Supporting Jack under Transmission case
18. Remove the ten Retaining cap screws from oil pan
and eight cap screw from hand hole cover
(17-3).
19. Attach a hoist to clutch housing then unbolt eight
bolts from out side and Four bolts from inside and
separate the clutch housing from transmission.
4. DISMANTLING 4
7
a. REAR PTO EXTENSION SHAFT AND SHIFTER
ASSEMBLY 5 3 5 1
1. Drive out the pin and remove shifter (5-2) From
the shaft.
2. Remove the gasket and bracket (3-2) from 6
the lever then remove the oil seal from bracket
(2-2). Fig. 4

cylindrical sleeve which is freely moving over a b. Remove the clutch housing from the
bearing retainer Hollow drive shaft transmission as detailed in para 4-b.
(10-1) is bolted to clutch housing partition with c. With draw the P.T.O. shaft from the rear of
gasket (14-1) to retain bearing hollow drive shaft. the transmission case.
d. Remove the thrust bearing (10-3) from the clutch NOTE : On tractors equipped with standard P.T.O. the
release Sleeve (11-3) counter shaft acts as the P.T.O. Front drive
5. ASSEMBLY shaft and this should be removed as detailed
Assembly is the reversal of the Dismantling in “Transmission” chapter if the spigot is
Procedure. damaged.
6. INSTALLATION 1. The clutch Housing C.R.P.T.O.
1. Installation is the reversal of the “Removal”. 2. Remove the P.T.O. compartment cover (21-
Procedure. 3) and hole cover (17-3) from the clutch
housing.
NOTE :
3. Separate the engine from the transmission
1. Tighten the clutch fork pinch two bolts after
case, taking care to avoid damage to the
inserting key clutch lever and spacer in
drive shafts.
between fork clutch release and tighten to
specified torque as detailed is specifications 4. Remove the P.T.O. shaft center along with
para. the splined coupling. (10-5).
2. Lubricate the bearing sleeve as detailed in
the “Operator’s Manual”. d. Hollow Drive shaft
7. REMOVAL 1. Remove the hollow shaft bearing retaining circlip
a. THE CLUTCH HOUSING C.R.P.T.O. (1-5) from hollow shaft.
a. Remove the clutch release mechanism as 2. Remove the retaining bolts of the drive shaft
detailed in “ENGINE CLUTCH” bearing retainer (8-5) and drive out hollow drive
shaft assembly with a suitable punch to the
181
1 2 3 4 5 6 7 8 Front.
3. Take out ball bearing (2-5) from the clutch housing
compartment.
4. Remove the circlip (5-5) and separate the outer
bearing (4-5) from the shaft (3-5).
10 11
14 15 5 Remove the oil seal (6-5) from the bearing retainer.
e. P.T.O Shaft Front.
1. Remove the four cap screws from end cover (18-5).
2. Remove the circlip (16-5) retaining 3 piece roller
bearing (15-5).
3. With a suitable punch drive P.T.O shaft front
(12-5) to the rear while holding up driven gear (13-
9 12 13 16 17 18
5) on P.T.O. shaft and take out from the clutch
Fig. 5 housing compartment.
1. Circlip 11. Circlip NOTE : Take care not to damage the front roller
2. Ball bearing inner 12. P.T.O Shaft front bearing.
3. P.T.O Hollow Drive shaft 13. P.T.O Driven gear
4. Ball bearing outer 14. Spacer
5. Circlip 15. Roller Bearing 8. CLEANING, INSPECTIONS & REPAIRS
6. Oil Seal (Three Piece) 1. Clean all the parts thoroughly.
7. Gasket 16. Circlip 2. For all the shafts, check the teeth of the splines
8. Bearing retainer 17. Gasket for any wear and / or chipping badly pitted teeth.
9. P.T.O Shaft centre 18. End cover
3. Inspect all bearing for cracks chipping or signs
10. Sliding coupling

of wear and check they rotate freely, lubricate the 1. Reverse the dismantling procedure.
bearings and wrap in grease of paper until required NOTE : On Tractors equipped with standard P.T.O.
for reassembly bearings and wrap in grease proof counter shaft, assemble the counter shaft
paper until required for reassembly. which acts as the P.T.O. front drive shaft as
4. Inspect the oil seal contact face on shaft. If it detailed in “TRANSMISSION” (Group 5).
is worn out or if chipping or distortion is evident, d. THE CLUTCH HOUSING C.R.P.T.O.
replace with the new shaft.
1. THE DRIVING SHAFT / HOLLOW DRIVE SHAFT
5. Replace the oil seal, and gaskets.
a. Press the oil seal (6.5) in the bearing retainer
6. Inspect the housings / retainers for cracks or (8-5) and Fix the gasket with shellac.
signs of damage.
b. Press the bearing (4-5) on shaft (3-5) and
7. Inspect the P.T.O. shifter forks and couplings for retain it with a circlip (5-5) see fig.6.
damages bends etc..
c. Insert the hollow drive bearing assembly in
8. Scrape of all gaskets from joint face. clutch housing from the front end and see
9. ASSEMBLY secure the bearing housing (8-5) with the
a. GENERAL bolts.
1. Extreme cleaning must be observed during d. Press the inner bearing (2-5) on the shaft from
assembly and installation. Bearings should
not be removed from their grease proof
wrapping until required for assembly and oil
openings should be covered to exclude
foreign matter.
2. New ‘O’ Ring oil seals and gaskets should
be used on assembly. The re-use of old seal
is false economy as leaks will not be evident
182 until the tractor is completely assembled.
3. Care must be taken not to damage oil seals
and protective sleeve should be used when
assembling sleeves over splines and threads.
b. REAR P.T.O. EXTENSION SHAFT & SHIFTER
ASSEMBLY
1. Press the bush (8-2) in to the shaft (9-2).
2. Press the bearing (11a-2) into the shaft install
the spacer (13-2) and bearing (11b-2).
3. Press the oil seal (12-2) in to the retainer (14-
2) with the lip towards the retainer flange.
Fig. 6
4. Slide the oil seal retainer complete with
gasket and oil seal onto the shaft using a rear end till it rest against the coller on the
protective sleeve. shaft and retain with circlip (1-5) on the shaft.
5. Install the circlip (7-2) then slide the clutch e. P.T.O. shaft Front CRPTO.
(6-2) onto the shaft with the flat face away
1. Install the P.T.O drive gear (13-5) in the
from the circlip.
clutch housing compartment. Align the drive
6. Press the oil seal (2-2) into the bracket (3- gear and insert P.T.O. shaft front (12-5) from
2) with the lip inwards. Rear end, align shaft spline and gear spline
7. Slide the lever (1-2) into the bracket. and push towards front. (see fig.7).
8. Assemble the shifter (5-2) locating the peg. 2. Use suitable dolly to hold shaft in center.
at 180º to the lever knob and secure with the 3. Install spacer (14-5).
groove pin.
4. Press Roller bearing (Three piece)
c. FRONT P.T.O. SHAFT

11. ADJUSTMENT
PTO drive gear The clutch pedal should be adjusted to give a
measurement of 6” between the pedal pad and foot
plate. This measurement is achieved by adjusting
the set sorew see fig.8.
Until the required measurement is obtained with
the clutch fully engaged the pedal should have
a free movement of 1/2”. The correct free
movement is obtained by loosening the retaining
bolt and move the pedal round the clutch release
shaft until the required adjustment has been made.
Ensure the retaining bolts are securely tightened.
For a dual clutch the hight of the clutch pedal
Fig. 7 above foot plate should be kept at 7” width of 1/
2”. Adjustment of pedal is as explained above.
NOTE : Take care that inner race facing is in side
then thrust coller. Then small ring on roller
bearing.
5. Secure roller bearing with a circlip. (16-5).
6. Install the end cover (18-5) with a gasket and
secure with cap screws with specified torque.
NOTE : Before torquing cap screws remove aligning
dollor fixture from rear.
7. Install the P.T.O. shaft splined coupling circlip
(11-5) in the coupling (10-5) bore.
8. Install the P.T.O. shaft center (9-5) in the 183
Fig. 8 Clutch pedal adjustment
P.T.O. shaft front easy for aligning with
counter shaft and clutch housing.
9. Install a gasket on transmission face with
shellac and assemble the clutch housing with
transmission in parallel direction to avoid
damage to the drive shaft. Check the free
rotation of both the drive shafts by hand.
10. Secure the cap screws attaching clutch to
the transmission.
11. Install the clutch release bearing (10-3) and
sleeve assembly (11-3) on the tube of the
bearing carrier. Apply grease to the carrier,
Install Fork (5-3) in position and insert clutch
release shaft secure the fork to the shaft with
a round key. Insert a circlip and secure the
clutch release shaft.
12. Assemble the engine on clutch housing.
13. Assemble P.T.O. shaft rear following the
removal processes in reverse order.
14. Assemble the bottom cover / oil pan and hand
hole cover with gasket and fill oil in
transmission case to the level plug mark.

Transmission
Notes :
184

GROUP - 7
Axle & Wheels
Specification
Description
Three Piece Adjustable Axle, Removal
Dismantling, Cleaning, Inspection & Repair
Single Piece Axle Removal
Dismantling, Assembly & Inspection
Trouble Shooting

Axle & Wheels
1. SPECIFICATIONS
Front axle pivot pin sleeve bushes I.D. (mm) ........ 29.97 — 28.44
(Pressed into position and reamed after assembly)
Pivot pin to bush clearance (mm) ........ 0.05 — 0.12
Front axle pivot pin bush length (mm) ........ 67.31 — 67.81
HEAVY DUTY ADJUSTABLE WIDE TREAD AXLE
Steering knuckle pivot shaft O.D. (mm) ........ 40.86 — 40.89
Steering knuckle bushes I.D. (mm) ........ 40.91 — 40.94
(Press into position and reamed after assembly)
Steering knuckle bush clearance (mm) ........ 0.02 — 0.07
Steering knuckle bush length (mm) ........ 72.77 — 73.28
Front axle pivot pin O.D. (mm) ........ 28.32 — 28.34
TORQUE LOADINGS
Front wheel nuts (lb ft) ....... 67.79 — 81.35
Rear wheel nuts (lb ft) ....... 271 —
Stay rod fixing nuts (lb ft) ....... 339 — 379.6
Front axle extension bolts (lb ft) ....... 339 — 379.6
Drag link and tie rod nuts (lb ft) ....... 74.5 — 81.35
Rear wheel rim bolts (Ib ft) ....... 149 — 155.91
Rear wheel rim bolts (Hi-Clear) (lb ft) ....... 54 — 67.8
Steering arm nut (lb ft) ....... 203.4 — 244
(Power Steering)
Bull gear retaining bolt (lb ft) ....... 284.7
186

Axle & Wheels
2. DESCRIPTION (b) Rear Axle

Two types of front axles are used on Mahindra The rear axle shafts are splined at the inner end
Tractors to their respective bull gears and carried by heavy
A) Three piece adjustable axle duty ball bearings mounted in the axle carrier.
B) Single piece axle Each bull gear and axle shaft is driven by a bull
pinion which is carried by a ball bearing and
driven from the differential.
A) THREE PIECE ADJUSTABLE AXLE (c) Front Wheels
(a) General The front wheels comprise a pressed steel rim
The adjustable front axles are of box section steel and attached tyre; within the rim is riveted a fixed
construction and the wheel tread is adjustable in position dished disc.
101.6mm increments. The axle pivots on a pin The disc is secured to the case hub by six
which passes through the front axle support and capscrews and wheel nuts. The inner and outer
is retained in position by a bolt, lockwasher and taper roller bearings within the hub are mounted
nut. The pivot pin sleeves are replaceable on the stub axle shaft and are completely sealed
bushings. The steering knuckle shafts turn in against dust or water. A slotted adjusting nut on
replaceable bushings pressed into the ends of the the stub axle shaft provides adjustment for the
axle extensions. wheel bearings.
1. The mechanical steering is of the single drop arm (d) Rear Wheels
design. The steering tie rod is the thompson type
The rear wheel comprises a pressed steel rim and
with one threaded end for obtaining correct front
attached tyre; within the rim is located and
wheel toe in while the other is adjustable in
adjustable inner dished disc position by lugs on
101.6mm increments to correspond to the front
the rim and secured by bolts and nuts.
axle tread adjustment.
Adjustment of the dished disc relative to the rim
lugs determines the track variation. The discs are
secured to the rear axle stubs by eight hub bolts
and nuts.
187
1. Socket 10. Steering knuckle pivot bush

2. Shims 11. Extension with bushes
3. Cap 12. Extension (LH)
4. Locking plate 13. Lock bolt for pin
5. Stay (Radius) rod 14. Extension RH
6. Pivot pin bush 15. Weight Front axle
7. Axle and bushes 16. Sleeve Front axle
8. Axle 17. Front axle bolt
9. Lubricator 18. Weight mounting bolt
Fig. 1 — Heavy Duty Front Axle & Stay Rod

Axle & Wheels
3. REMOVAL
a. The Front Axle Stay (Radius) Rod
1. Turn down the locking plates (4-1) and
remove the three securing capscrews.
2. Remove the socket cap (3-1), shims (2-1)
and socket (1-1).
3. Remove the two nuts retaining the stay rod
(5-1) to the front axle.
4. Slide the stay rod clear of the front axle.
Fig. 3
NOTE (1) : The front end of the pivot pin is

threaded for the fitting of an extractor
bolt.
(2) : The pivot pin can be lightly tapped out
from the rear of the axle support, but
care must be taken not to damage the
3 2 shims which are installed between the
axle and axle support when the standard
adjustable axle is fitted.
6. Raise the front end of the tractor until the axle
support is clear of the axle then roll the front
Fig. 2 axle assembly out and clear of the tractor.
Mechanical Steering 7. Place the front axle on stand.
188
b. Removal of Adjustable Front Axle c. The Rear Axle
1. Lock the brakes and securely chock the rear 1. Drain the transmission and hydraulic lift
wheels for safety. housing.
2. Disconnect the drag link (1-2) by removing 2. Jack up the rear of the tractor until the rear
the cotter pin and nut (3-2) or by wheels are clear of the ground and supported
disconnecting two Hydraulic pipes of power securely on wooden blocks.
steering (1-2a), if power steering is fitted. NOTE : If the front axle is in position drive wooden
3. Support the front of the tractor with a suitable wedges between the axle support to prevent
hoist or hydraulic jack positioned under the the tractor rolling about the axle pivot pin.
clutch housing and lift the weight from the 3. Remove the eight nuts (2-4) securing the rear
front axle. wheels.
4. Remove the securing nut and lock-washer 4. Disconnect the rear light cables from the
then drive out the bolt (1-3) securing the axle Multisocket.
pivot pin (2-3) or remove the lock plate
5. Remove the rear fenders.
(3-3a) securing front axle pivot pin by
NOTE : The handbrake lever assembly is attached to
removing two bolts (1-3a)
the right hand fender, disconnect the operating
5. Remove the axle pivot pin (2-3) from the axle to foot pedal as detailed in “BRAKES” (cable)
support.

Axle & Wheels
1. Rear wheel
2. Securing nut and bolt
3. Cap
4. Gasket
5. Felt washer
6. Oil seal
7. Outer bearing
8. Axle shaft
9. Axle carrier
10. Collar
11. Inner bearing
12. Circlip
13. Bull gear
14. Shims
15. Retainer washer
16. Capscrew and lock washer
17. Gasket
Fig. 4 — The Rear Axle

6. Remove the hydraulic lift housing as detailed
in “HYDRAULICS”
3 1 2
7. Remove the rear P.T.O. shaft as detailed in
“POWER TAKE-OFF”
8. Remove the securing capscrew and
lockwasher (16-4), retainer washer (15-4) and
shims (14-4) from the axle shaft (8-4).
NOTE : The bull gears should be marked at this stage
to ensure assembly in their original positions. 189
9. Support the axle housing then remove the ten
capscrews and lockwashers (1-5) securing
the axle assembly to the transmission case.
10. Remove the axle housing (2-5) from the Fig. 5 — The Rear Axle
transmission case (3-5) and bull gear
(13-4). 4. DISMANTLING
a. The Front Wheels And Hubs
WARNING : Damage may occur to the bull gear
teeth or transmission case if the bull gear is allowed 1. Remove the six securing nuts (13-7) and lift
to drop when removing the axle housing. the wheel clear of the hub.
11. To remove the bull gears from the 2. Remove the three hub cap securing screws
transmission case, tilt the gear inwards from (1-6) then lift off the hub cap (3-6) and gasket
the bottom and lift clear. (2-6).
NOTE : To Remove a Bull gear without removing the 3. Remove the cotter pin (4-6) and screw off the
Rear axle, Unbolt rear P.T.O shaft bearing slotted adjusting nut (5-6), remove the bearing
retainer and remove P.T.O shaft. The Bull retainer washer (6-6).
gear can now be removed. However, the left 4. Pull the wheel hub (6-7) from the stub axle.
bull gear must be out of housing before
enough clearance is available to lift out the NOTE (1) : The wheel and hub can be removed as
right bull gear. an assembly (see Fig. 8).

Axle & Wheels
1. Hub capscrew
2. Gasket
3. Hub cap
4. Cotter pin
5. Nut
6. Bearing retainer washer
7. Outer front wheel bearing
8. Outer bearing cup
9. Outer grease retainer
10. Inner grease retainer
11. Inner bearing cup
12. Inner front wheel bearing
13. Felt washer
14. Oil seal
15. Spacer
16. Felt washer
17. Dust shield
18. Steering arm
19. Bushes
20. Front axle extension
21. Thrust bearing
22. Axle
23. Axle extension securing bolts
Fig. 6 - Front Axle Wheel Assembly
1. Front wheel hub bolt

2. Front wheel hub complete
3. Felt washer retainer
190 4. Inner bearing
5. Grease retainer
6. Front wheel hub
7. Grease retainer
8. Outer bearing
9. Outer bearing retainer
10. Castellated nut
11. Hubcap gasket
12. Hubcap
13. Nut
Fig. 7 - Front Wheel Hub mahindra

Axle & Wheels
(2) : The outer bearing cone and cup (8-7), 6. Pull the thrust bearing (7-9) from each steering
grease retainer (7-7), grease retainer (5- knuckle shaft.
7), inner bearing cup (4-7) and the felt 7. Pull the oil seal (17-10) and (16-10), felt
washer retainer (3-7) will come away washer (15-10) and dust shield (14-10) from
with the hub. the stub axle shaft.
5. Remove the inner and outer bearing cups c. The Rear Axle
from the hub then remove the inner and outer
1. Remove the four capscrews securing the
grease retainers.
bearing retainer (2-13) to the axle housing.
6. Pull the inner bearing (4-7) from the stub axle
shaft.
191
Fig. 8
(b) The Adjustable Wide Tread Axle Fig. 9
1. Remove the wheels and hubs as detailed in
2. Press the axle shaft (1-12) out of the inner
para 5a.
bearing (3-12) and axle housing.
2. Remove the nut (3-9) and bolt (4-9) then lift
NOTE : The outer bearing (3-13) and collar (10-4)
the steering knuckle arm (5-9) off the key
should come away with the axle.
(6-9) and clear of the shaft.
3. Remove the key (6-9) then remove the 3. Draw the outer bearing (3-13) from the shaft
steering knuckle (8-9) complete with thrust then slide off the bearing retainer (1-13)
bearing (7-9) from the axle extension (2-9). complete with oil seal (4-13) and felt washer.
4. Remove the nut and drive out the spacers 4. Remove the oil seal (4-13) and felt washer
bolt (4-2) then slide out the axle extension. from the bearing retainer (1-13).
5. Press the two bushes (1-9) from each axle 5. Remove the circlip (2-12) and pull out the
extension if inspection proves this necessary. inner bearing (3-12).

Axle & Wheels
Fig. 10 - The Standard Steering Axle

1. Steering knuckle 9. Clip assembly (LH)
complete (RH) 10. Tie rod end (threaded) Fig. 12
2. Thrust bearing 11. Steering drag link 3. Inspect all pivot shafts and bushings for wear
3. Steering knuckle 12. Steering knuckle arm (LH) or damage.
arm (RH) 13. Steering complete (LH)
4. Lubricator 14. Dust shield
4. Inspect the axle components for distortion
5. Tie rod complete 15. Felt washer and cracks particularly adjacent to welds.
6. Tie rod end 16. Spacer 5. Inspect all ball joints for excessive play.
7. Clip assembly (RH) 17. Oil seal
8. Nut & Washer 6. Inspect the splines of the axle shafts and bull
gears for wear or damage.
5. CLEANING, INSPECTION & REPAIR
7. Replace all faulty parts and fit new oil seals
1. Clean all parts thoroughly in a suitable solvent and gaskets on assembly.
and blow dry with compressed air.
192 6. ASSEMBLY
2. Inspect the bearing for cracks scores and
a. The Rear Axle
general wear. Repack the bearings if proved
satisfactory for reassembly, with the correct 1. Replace the felt washer and oil seal (4-13)
type of grease and wrap in grease proof paper into the bearing retainer (1-13) then slide the
until required. retainer onto the axle.
NOTE (1) : When fitting the oil seal (4-13) into the
bearing retainer the lips of the seal must
face upwards (toward the inside of the
axle).
NOTE (2) : To ensure that the oil seal, is not
damaged when passing over the axle
shaft splines, tape the splines.
2. Press on the outer bearing (3-13).
3. Install a new gasket between the bearing
retainer and axle housing.
4. Slide the axle into the housing and press the
bearing home.
5. Install the four bearing retainer cap-screws.
Fig. 13

Axle & Wheels
6. Assemble the axle collar (10-4) then press 3. Press the grease retainers (5 & 7-7), the inner
the inner bearing (3-12) onto the axle and into and outer bearing cups (4 & 8-7) into the hubs.
the housing. NOTE : Press in the felt retainer (3-7) if removed.
7. Install the circlip (2-12).
b. Front Axle Assembly 4. Slide the hubs onto the stub axle shaft, install
1. Press the bushings into the axle ends. the outer bearing cone (8-7) and bearing
NOTE : New bushes must be line-reamed after retainer (9-7).
assembly. Refer to “ SPECIFICATIONS” para. NOTE : Pack front wheel bearings with the correct
2 for reaming dimensions. type of grease before final assembly.
2. Slide the axle extensions into the axle center 5. Screw on the nut (10-7) and adjust the bearings
section and secure at the desired track width as detailed in “ADJUSTMENTS”.
with sleeves bolts and nuts. Refer to
6. Secure the nut with a cotter pin then install
“SPECIFICATIONS”, para. 2, Torque
the hub cap with new gasket and secure with
Loadings (if three piece axle is fitted)
three capscrews and lockwasher.
NOTE (1) : The steering knuckle shaft is slightly off-
7. Place the front wheel on the hub and secure
set to the centre line of the axle
with six nuts. Refer to “SPECIFICATIONS”,
extension. This off-set MUST be
para. 2.
towards the rear of the tractor.
7. INSTALLATION
(2) : The head of the bolt will be clear of the
axle center section when tightened. This a. The Rear Axle
is intentional and washers MUST NOT 1. Install a new gasket then slide the axle and
BE INSERTED. housing into the transmission case engaging
3. Pack the thrust bearing (7-9) with the correct the axle splines in the bull gear.
type of grease and install on each pivot shaft NOTE : This operation will be facilitated if two or three
making sure they are assembled the correct guide pins are screwed into the transmission
way up. ‘TOP” is stamped on the bearing. housing to support the axle housing and
4. Lubricate the axle extension bushes with the locate the bull gears on the axle splines.
correct type of grease then slide the steering 2. Insert and tighten the attaching cap-screws.
knuckle shaft (8-9) through the bushes. 3. Install the bull gear retainer with cap-screw
193
5. Fit the key (6-9) and assemble the steering and lockwasher after inserting the correct
knuckle arm (5-9) locating on the key way shims (refer to “ADJUSTMENTS”. See Fig.
and pinch bolt slot. 14 & 14a.
6. Secure the steering knuckle arm by inserting 4. Tighten the bull gear retaining cap-screw to
the pinch bolt (4-9), and nut. the specified torque. Refer to “SPECIFICA-
7. Assemble the tie rods ball ends into the TIONS”, para.2. Torque Loadings.
steering knuckle arms and secure with slotted 5. Replace the rear P.T.O. shaft as detailed in
nuts and cotter pins. “POWER TAKE-OFF’.
c. The Front Wheels And Hubs 6. Replace the hydraulic lift housing as detailed
in “HYDRAULICS”.
1. Press the dust shield (14-10), felt washer (15-
10), spacer (16-10) and oil seal (17-10) onto 7. Install the rear fenders, then connect the
the stub axle shaft. parking brake and adjust the brakes. Connect
the rear light cables.
NOTE (1) : Front oil seals are to be assembled with
lip turned away from the grease chamber 8. Install the rear wheels and tighten the eight
to serve as dust seal. securing capscrews to the specified torque.
Refer to “SPECIFICATIONS”, para. 2 Torque
NOTE (2) : Soak felt washers in oil before installing.
Loadings.
2. Press the inner bearing cone (4-7) onto the
9. Fill the transmission housing with the correct
stub axle shaft.
grade of oil to the transmission oil level plugs.

Axle & Wheels
2. Shims can be removed or inserted until the

correct ball end free rotating movement is
obtained.
3. Tighten the three capscrews and secure with
lock plates.
4. Torque the stay rod securing nuts. Refer to
“SPECIFICATIONS”, para.2. Torque Loadings.
b. The Front Axle Pivot Pin
1. Insert the pivot pin through the axle pivot
tube but not into the rear of the axle.
NOTE : When a stay rod is fitted no shims are
required. The axle must be clear of the front
and rear faces of the axle support allowing
the stay rod to take all the axle thrust.
Fig. 11
2. With the axle held square against the front
b. The Front Axles bearing, insert a number of shims necessary
to enable the axle to swing freely but without
1. Position the front axle assembly under the
end float.
front axle support and insert the pivot pin
(2-3). 3. Lightly drive the pivot pin into the rear axle
support bearing and insert the securing nut,
2. Align the holes in the pivot pin and axle
lockwasher and bolt.
support, then lightly drive in the pin (2-3) and
tighten the lockwasher and nut (1-3) for new c. The Front Wheel Bearings
type of pivot pin align the lock plate holes 1. Tighten the front wheel retainer nut to a torque
and axle support bracket (see fig 3A) then of 67.7 Nm while rotating the wheel to ensure
lightly drive the pin and tighten the lock auto correct seating of the bearings.
bolts. 2. Loosen the retainer nut gradually until the thrust
3. Connect the drag link to the left hand washer can be turned by hand. Insert the cotter
steering knuckle and secure with slotted nut pin if possible, if not continue loosening the
and cotter pin or power cylinder Hydraulic retainer nut until the first slot aligns with the drilled
194
pipes. hole then insert the cotter pin.
4. Adjust the steering linkage as detailed in NOTE : The above method ensures that the bearings
“ADJUSTMENTS” are not pre-loaded. UNDER NO
5. Grease all points. CIRCUMSTANCES MUST THE NUT BE
TIGHTENED TO ALIGN A SLOT AFTER
c. The Stay Rod
THE THRUST WASHER BECOMES FREE.
1. Slide the stay rod into the front axle lugs and ALWAYS LOOSEN OFF TO THE FIRST
install the nuts. SLOT IN THE RETAINER NUT.
2. Attach the ball end to the clutch housing by d. Wheel Alignment
means of the socket (1-1), shims (2-1),
1. Ensure the wheels are in the straight ahead
socket cap (3-1), three cap-screws and lock
position on a level surface.
plates (4-1).
2. Measure the distance between the forward
3. Adjust the ball end shims as detailed in
outer edges of the wheel rims at hub height
“ADJUSTMENTS”.
and mark the positions.
8. ADJUSTMENTS
3. Rotate the wheels one half turn so that the
a. The Stay Rod Ball Socket marks are to the rear at hub height.
1. With the stay rod to axle nuts loose, the ball 4. The distance between the marks should now
end of the stay rod must be free to rotate in be 0-1.58mm wider than the previous
its socket but there must be no free play measurement.
between the ball and socket.

Axle & Wheels
5. Adjust by means of the adjustable ball end NOTE : If a depth gauge is not available, insert soft
on the tie rod then tighten the locknut lead strip between the face of the axle shaft
securely. and retainer washer then tighten the retainer
e. Drag Link bolt to the correct torque value. The soft lead
strip can be measured with a micrometer
Refer to steering adjustment.
when removed, and shims of the correct
f. Bull Gears dimensions can be fitted to give a clearance
1. A clearance of 0.0 - 0.127mm MUST be of 0.0 - 0.127mm.
maintained between the axle face and bull 3. Insert the shims (4-11) retainer washer
gear retainer washer. (fig 14a.) (3-11), lockwasher (2-11) and secure with the
2. Measure the distance from the face of the retainer bolt (1-11).
bull gear hub (5-11) to the end face of the 4. Torque the retainer bolt. Refer to
axle shaft with a depth gauge and subtract “SPECIFICATIONS” para.2. Torque Loadings.
the required clearance.
195
Fig. 14
Fig. 14A

Axle & Wheels
B. SINGLE PIECE FRONT AXLE 3.Removal
The single piece front axles of are box section steel 1) Lock the brakes and securely chock the rear
construction. The axle pivots on a pin which passes wheels for safety and apply the parking brake.
through the front axle support and is retained in 2) Block the front axle support casting and axle
position by lock plate secured by lock washer and nut beam both the side to prevent the assembly
in slot which is provided on pin. The pivot pin sleeves
tilting.
ate replaceable bushings. The steering knuckle shafts
turn in replaceable bushings pressed into the and of 3) Loosen the front wheel nuts.
the axle. A thrust bearing allow turning action and take 4) Lift the front of the tractor with a suitable floor
load. side under the engine oil pan or with hoist. Remove
Front axle Support is heavy duty casting with bore in the front wheels.
it’s front and rear lug for pivot pin. Provision for battery 4) Support the tractor under engine or clutch housing
mounting trays bracket for power steering cylinder ball
using strong trestle with a wooden top. Remove
jointed.
the floor jack or hoist.
The steering tie rod is threaded end of obtaining
correct front wheel toe-in. 5) Sling the axle securely and with a suitable hoist
tension the sling.
6) Remove the securing lock plate bolts (3-3) and
lock plate (4-3) then drive out / pull out the pin
(5-3) from the axle support.
NOTE : The front end of the pivot pin is thread for
the fitting of an extractor bolt (1/2”-13 UNC).
7) Raise the front end of the tractor until the axle

support is clear of the axle assembly out and
clear of the tractor.
4.Dismantling inspection repair and assembly
a. The front wheel hubs
For details refer Para 4
b. Axle knuckle
1) Remove the tie rod (12-4) by removing the cotter
196 pins, slotted nut and bolts (15,16,17-4) then
tapping the ball ends from steering knuckle arms.
1
2
4 3
Fig. 1 5
1 Front axle 9 Washer
2 Bush front axle pivot pin 10 Bush
3 Nipple 11 Bush Fig. 2
4 Bush steering knuckle 12 Pivot pin front axle
5 Support front axle 13 Plate pivot pin 1. Power steering hose 5. Knuckle arm lower
6 Bolt 14 Locking plate pivot pin 2. Front axle 6. Tie rod end
7 Bolt 15 Bolt 3. Tie rod 7. Power steering
8 Bolt 4. Knuckle arm upper cylinder

Axle & Wheels
2 6) Pull out the oil seal, felt washer, and dust shield
from the stub axle shaft.
5.Assembly
a.One piece front axle
6
1) Press the bushing in to the axle ends
NOTE : New bushes must be line reamed after
assembly refer ‘Specifications’
3 2) Pack the thrust bearing with the correct type

of grease and install on each pivot shaft
4 1
5 making sure they are assembled the correct
1. Front axle
Fig. 3
4. Lock plate way.
2. Axle support 5. Pivot pin 3) Lubricate the axle knuckle shaft bushes with
3. Bolt 6. Mounting bolt
the correct type of grease then slide the
2) Remove the nut and bolt (7,6-4) then lift the steering knuckle shaft (1,2-4) through the
steering knuckle arm (5-4) off the key (3-4) and bushes.
clear of the shaft, then remove the steering 4) Fit the key (3-4) and assemble the steering
knuckle (2-4) complete with thrust bearing (4-4) knuckle (7-4) locating on the key way and
from the axle pinch bolt slot.
3) Remove the nut (11-4) and bolt (10-4) from arm 5) Secure the steering knuckle arm by inserting
steering knuckle (15-4) this knuckle is fitted at the pinch bolt (6-4) and nut.
the bottom of L.H. knuckle (1-4). 6) Fit the key (9-4) on L.H. knuckle shaft lower
4) Press the two bushes (2-1) from axle end if and assemble the knuckle arm steering
inspection proves this necessary. (15-4) locating key way and pinch bolt slot
5) Pull out the thrust bearing (4-4) from the steering, then secure the arm by inserting bolt (10-4),
nude shaft. lock washer and tighten nut (11-4) to the
same specified torque.
7) Assemble the tie rod ends into the steering
6
arms and secure with slotted nuts and cotter
13 pins.
197
14 7 5
13 6.Installation
15
a)Front axle
14 3
16 1) Position the front axle assembly under the
17 2
front axle support and insert the pivot pin (5-
12 4
3).
7 6 2) Align the slot on the pivot pin (5-3) and lock
5 plate (4-4) to align bolt holes on axle support
3 1 then lightly drive the pin then secure the plate
15 (4-3) by two bolts (3-3) to the specified
11
torque.
9
3) Connect the steering cylinder one and ball
10
joint to the axle bracket and other end to the
Fig. 4
left hand steering knuckle arm lower (15-4)
1. Knuckle steering RH 10. Bolt
2. Knuckle steering LH 11. Nut and secure with slotted nut and cotter pin.
3. Key woodruff 12. Rod tie 4) Connect the power steering hydraulic pipes.
4. Bearing thrust 13. Bolt
5. Arm steering knuckle 14. Clip tie rod 5) Adjust the steering link age as detailed in
6. Bolt 15. Pin cotter “ADJUSTMENT”.
7. Nut 16. Nut
8. Arm steering knuckle LH 17. Washer 6) Grease all the points
9. Key woodruff 18. End tie rod LH/RH

Axle & Wheels
9. TROUBLE SHOOTING
A.
(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
binding, shafts and bushings for
seizure or lack of
lubrication.
(c) Work or damaged (c) Check drag link, drop
steering linkage, arm, 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,
gear assembly, drag link, steering
knuckles and pivot
pin sleeve.
198 (b) Incorrect toe-in. (b) Check and adjust toe-in.
B.
(1) Noisy final drive. (a) Insufficient lubrication, (a) Check oil level.
(b) Work bearings causing (b) Inspect bearings and
misalignment, replace if necessary.
(c) Excessive or insufficient (c) Check backlash and
backlash and/or faulty reset if necessary.
bull gear and pinion. Inspect bull gears and
pinions for wear or
damage.

GROUP - 8
Brakes
Chapter 1 - Mechanical Brakes
Chapter 2 - Lubritech (Oil Immersed Brakes)

Brakes - Mechanical Brakes
Chapter-1 Mechanical Brakes

Specification
Description
Removal & Dismantling of Mechanical Brakes
Cleaning Inspection, Repair & Installation
200

1. SPECIFICATIONS
Cross shaft O.D. (mm) ... ... ... ... ... ... 34.82 - 34.92
BRAKE LINING
No. used ... ... ... ... ... ... ... 203
Lining 0.0. (mm) ... ... ... ... ... ... 165
Lining I.D. (mm) ... ... ... ... ... ... 88.9
Function area (each) (mm) ... ... ... ... ... ... 598.47
FOOT PEDAL RETURN SPRINGS

Free length (mm) ... ... ... ... ... ... 184.15
Test length (mm) ... ... ... ... ... ... 247.65
Test load (Ib) ... ... ... ... ... ... 0.45kg
2. DESCRIPTION
The brakes are mechanical, double disc type 3. REMOVAL
mounted on the bull pinion shaft. These brakes
are self-energising; the natural movement of the a. The R. H. Brake Assembly
various components is used to increase braking 1. Release the parking brake operating cable (3-
action once it is started by the foot pedal. 1) by removing the cotter pin (1-1) and clevis
The brakes are controlled by two foot pedals and pin (2-1).
one hand lever which operate on a cross shaft. 2. Release the RH fender from the axle and
The two foot pedals can be operated individually footplate, then move it to the rear.
or locked together to operate simultaneously. The NOTE : It is unnecessary to remove the fender or
hand lever is used as a parking brake only. disconnect the rear lighting leads to give the
Application of one foot pedal slows the rear wheel required clearance for removing the brake
on the side applied. Differential action speeds up housing.
the other wheel in the same ratio the braked wheel 3. Remove the two pedal return springs (2-2).
slows down, thus accelerating the turning of the 4. Remove the cotter pin and washer (3-2) then
tractor and reducing the turning radius. tap the clevis pin (4-2) from the foot pedal
When the two pedals are latched together, both adjuster levers.
brakes will operate in unison and the same braking 5. Remove the differential lock lever return
effort will be imposed on both wheels. The pedals spring from the anchor plate.
can be locked with the hand lever in the engaged
position for parking the tractor. 6. Remove the four capscrews and lock-washer
(1-2) securing the brake housing assembly to
the bull pinion cage (5-2). 201
7. Remove the brake housing assembly from
the bull pinion shaft (see Fig. 3).
Fig. 1 Fig. 2

8.
Remove the inner friction disc from the bull 5.Remove the cotter pin and bush brake pedal
pinion shaft. cross shaft (2-5) from the (RH) side of the
NOTE : The outer friction disc and actuating discs will cross shaft then slide the (RH) brake pedal
come away with the brake housing. (1-5) off the cross shaft.
6. Remove the two pinch bolts and cross shaft
b. The L. H. Brake Assembly keys (6-5) from the (LH) brake pedal and
1. Removal of the brake housing assembly is brake lever (3-5).
identical to the (RH) brake assembly with the 7. Remove the (LH) brake lever (8-5), then slide
exception of ops. 2 & 5, para. 3a. the cross shaft through and out of the (RH)
side removing the (LH) foot pedal.
4. DISMANTLING
a. The R. H. Brake Assembly
1. Unscrew the adjusting lock nut (18A-6) and
remove the adjuster bolt (18-6) from the
trunnion (17-6).
2. Remove the cotter pin, washer and pivot pin
then remove the trunnion (17-6) from the
brake operating levers (15-6).
3. Remove the cotter pin and washer from the
brake pivot pin (13-6) then withdraw the pivot
pin from the operating levers (15-6).
Fig. 3 4. Remove the cotter pin and washer from the
tension linkage pin (14-6) then withdraw the
c. The Parking Brake Lever Assembly
pin from the operating levers.
1. Release the parking brake operating cable as
NOTE : The brake operating levers (15-6) are removed
detailed in op. 1 para. 3a.
in two parts (see Fig. 6).
2. Remove the parking brake hand lever
assembly from the (RH) fender by removing 5. Remove the rubber boot (10-6) then lift out
the three nuts and lockwashers (2-4) then the brake actuating disc assembly from the
withdraw the three bolts and spacers (3-4) brake housing.
from the fender. 6. Lift out the outer brake disc.
d. The Brake Cross Shaft 7. Remove the cotter pin (11-6), washer
1. Remove the right hand rear road wheel. (22-6) and withdraw the jaw pin (21-6) from
2. Disconnect the parking brake lever operating the actuating linkage.
cable as detailed in op. 1 para. 3a. 8. Remove the nuts and lockwashers (20-6)
3. Remove the pedal return spring as detailed then withdraw the pivot pins (19-6) from the
in op. 3 para. 3a. linkage and actuating disc.
4. Remove the clevis pins from the (LH) and 9. Remove the three return springs (7-6) to
(RH) foot pedal adjusters as detailed in op. separate the two actuating discs.
202 10. Remove the five actuating balls.
4 para. 3a.
11. Remove the two capscrews and lock-washers
(4-1) then remove the differential lock pedal
thrust plate (5-1).
12. Remove the differential lock pivot bolt (6-1)
then remove the lock pedal (7-1).
13. Press the oil seal from the brake housing.
b. The L. H. Brake Assembly
1. The dismantling procedure is identical to the
(RH) brake assembly with the exception of
ops. 11, 12 & 13 para. 4a.
c. The Parking Brake Lever Assembly
1. Remove the attaching plate (2-7) from the
parking brake assembly (4-7), by removing
the two nuts and lockwashers then withdraw
the bolts, outer spacers (3-7) and inner
spacers (12-8).
Fig. 4

2. To remove the parking brake connecting rod,
remove the cotter pin and washer then
withdraw the clevis pin (11-8) from the clevis
(5-7) and link (9-8).
3. To remove the adjuster knob, unscrew the
outer half (2-8), inner half (3-8) then remove
the spring (4-8) and ball (5-8) from the lever
assembly (6-8).
5. CLEANING, INSPECTION & REPAIR
1. Wash all parts except the brake linings in a
suitable cleaning solvent and blow dry with
compressed air.
2. Inspect the actuating balls for pitting, cracks,
scores or heat damage.
3. Check the actuating disc surfaces for scores or
grooves, and ball seats for excessive wear or
damage.
4. Inspect the disc plates and linings for wear,
grease or oil contamination, cracks or glazing.
5. Inspect the linkage for wear.
6. Check the actuating disc springs and discard if
they show any signs of being weakened, or if the
spring ends are deformed.
7. Replace all worn or faulty parts.
6. ASSEMBLY
a. The R. H. Brake Assembly
1. Fit a new differential lockshaft oil seal into
the brake housing with the seal lip facing
Fig. 5 outwards.
1. R.H. Brake Pedal 5. Key woodruff 2. Assemble the differential lock pedal and
2. Bush Brake Pedal Shaft 6. Shaft Brake Pedal secure with pivot bolt.
3. Pin 7. L.H. Brake Pedal 3. Fit the differential lock pedal thrust plate
4. Return spring 8. Cable Hand brake (5-1) to the brake housing and secure with
two capscrews and lockwasher (4-1).
4. Place one actuating disc flat on a bench with
the ball seat ramps facing up-wards.
1. Brake housing RH. 16. Nut 203

2. Friction disc 17. Trunnion
3. Actuating disc unit 18. Footbrake
4. Actuating disc adjuster bolt
assembly 19. Pivot pin
5. Actuating disc 20. Locknut
6. Ball 21. Jaw pin
7. Return spring 22. Washer
8. Link 23. Joggle link
9. Tension link
10. Rubber boot
11. Cotter pin
12. Washer
13. Brake pivot pin
14. Tension link pin
15. Brake operating lever
Fig. 6 - Exploded View of The Disc Brake Assembly

5. Place the five balls (6-6) in the ramps then
position the second actuating disc on the balls
aligning the attaching lugs.
6. Install the three actuating springs (7-6).
7. Assemble the linkage to both actuating discs
with pivot pins (19-6) and secure with nuts
and lockwashers (20-6).
8. Insert the jaw pin (21-6) into the actuating
linkage (8 & 9-6) to complete the linkage
assembly.
9. Place the outer disc plate into the brake
housing (1-6).
10. Replace the brake actuating disc assembly
and rubber boot (10-6) into the housing.
11. Assemble the two parts of the operating lever
(15-6) and insert the tension linkage pin
(14-6) through the operating lever and tension
links (9-6).
Fig. 8
c. The Parking Brake
“ASSEMBLY” is the reversal of the dismantling
procedure.
7. INSTALLATION
a. The Brake Cross Shaft
1. Slide the cross shaft (6-5) through the clutch
housing bores from The right hand side
attaching the left hand brake pedal as the
shaft is installed.
2. Install then fit the keys (5-5) and secure left
hand foot pedal (7-5) bolts.
3. Slide the bush (2-5) right hand brake pedal
204 (1-5) and bush onto the cross shaft then
secure with washer and cotter pin.
4. Apply a grease gun to both lubricating points.
Fig. 7
b. The R. H. Brake Assembly bolts.
1. Spacer 3. Spacer 5. Clevis 7. Pin
2. Plate 4. Lever 6. Cable 1. Place the inner friction disc on the bull pinion
shaft and slide the disc up to the face of the
12. Insert the brake pivot pin (13-6) through the bull pinion housing.
operating lever and brake housing, then secure 2. Install the brake housing assembly over the
with washer and cotter pin. pinion shaft, engaging the splines on the
13. Replace the trunnion (17-6) and pivot pin, then shaft with those of the outer friction disc.
secure with washer and cotter pin. 3. Secure the brake housing to the bull pinion
14. Replace the foot brake adjuster bolt (18-6) housing with four capscrews and lockwashers
into the trunnion (17-6) and screw on the (1-2).
adjuster nuts. 4. Replace the differential lock lever return
b. The L. H. Brake Assembly spring.
1. The assembly procedure is identical with NOTE : For details of adjustments to the differential
the right hand brake assembly except for lock lever and thrust plate, Refer
1, 2 & 3 para. 6a. “DIFFERENTIAL”.

5.
Install the footbrake adjuster bolt (18-6) to the bottom of the housing
right hand foot pedal and insert the clevis (4- ii) Insert the Pressure air hose in breather
2), washer (3-2) and cotter pin.
iii) Blow the air till all dust comes out from the
NOTE : Assembling the footbrake adjuster bolts to the drain hole.
outer holes in the foot pedal and brake lever
gives a ratio of 18:1 and free pedal b) Brake setting
movement of 1-3/4 inches. i) Jack up the rear RH tyre.
6. Replace the pedal return springs (2-2). ii) Loosen the actuating disc stopper bolt (fig.
7. Install the right hand fender. 9)
c. The L. H. Brake Assembly iii) Loosen the Lock nut ‘A’ of brake linkage
(fig.10)
1. Installation is identical to the right hand brake
housing assembly, except for adjustments to iv) Tight the adjusting nut ‘B’ of brake linkage
the differential lock pedal. (fig.10)
d. The Parking Brake v) Check the brake paddle for free play of 15-
1. Install the parking brake hand lever assembly 20 mm. If free play found more, tight the
to the fender by placing the spacers (3-4) on adjusting nut ‘B’.
each bolt, then insert the three bolts through vi) Tighten the lock nut ‘A’ (fig.10)
the fender and secure with nuts and vii) Screw in the actuating stopper bolt such that
lockwashers (2-4). it just ouches the actuating disc. (Get the feel
2. Connect the operating rod (3-1) to the brake of bolt touching to disc). (fig.9)
lever then insert the clevis pin (2-1) and cotter viii) Tighten the check nut of stopper bolt.
pin (1-1).
ix) Repeat the same procedure to LH side
3. Replace the rear wheel. Refer to
c) Bedding in - If brake performance is not
“SPECIFICATIONS WHEELS & AXLES” for
satisfactory on new brakes or with liners, carry out
the correct torque loading.
the bedding of liners in as follows.
4. Refer to the Operators Manual for details of
parking brake adjustments. i) Loosen the actuating disc Check nut &
stopper bolt .
ii) Run the tractor in L-2 gear at 1500 RPM,
8. 7.5” BRAKES apply the equal brakes & run the tractor for
7.5” Brakes are Introduced on 595 DI Super Turbo 30 meters. (Ensure ‘No’ stalling of tractor).
Tractor iii) Carry out this activity only once.
Features of New Brakes are as follows. iv) Run the tractor in reverse gear & stop it by
1) Asbestos free liners for longer life. sudden braking.
2) Actuating springs increased from 4 to 5 v) Check the brake setting. Adjust if required.
vi) Test the tractors for equal braking & ‘Tuk’
3) Zinc plating on actuating disc to avoid
Noise.
corrosion.
4) Actuating disc stopper bolt for smooth during
205
braking operation.
5) Bigger breather for enhanced heat
dissipation.
6) Mounting bolts increased from 6 to 7 for
better sealing.
7) Drain plug (M-24) for cleaning brake liner dust Fig. 9
without removing housing.
8) Improved linkage sealing (Seal type inplace
of bellow type).
9) Wear Lugs deleted from actuating disc.
Service Instructions
a) Cleaning of dust - Brake lining dust can be
cleaned without dismantling the brake assembly.
i) Remove the drain plug provided at the Fig. 10

Brakes - Lubritech (Oil Immersed)
Chapter-2 Lubritech Brakes (Oil Immersed)

Brake Dismantling Procedure
Brake Fitment Procedure
Do’s & Dont’s
206

A) BRAKE DISMANTLING PROCEDURE 5. Insert the intermediate plate no.1 then the
1. Disconnect the brake pedal return spring friction disc no.1 as per the sequence given
(fig-3) 6. Intermediate plate lugs must be properly
2. Loosen the turnbuckle lock nuts and loosen seated.
the turnbuckle to remove the pin connecting 7. The sequence is 3 intermediate plate + 3
turnbuckle and brake lever. friction disc towards housing end and 2
3. Remove the circlip and remove the brake intermediate plate + 3 friction disc towards
lever from the operating cross shaft. cover end.
4. Loosen the auto swing arrestor end cover and 8. Fit the diff lock oil seal & cross shaft oil on
remove the adjuster sub assy. the end cover.
5. Loosen the brake end cover mounting bolts 9. Fit the operating cross shaft on actuating disc
and carefully remove the end cover such that pull rod.
the last friction disc should not fall on the 10. Fit the gasket onto the housing sealing profile
ground. and mount the end cover onto the brake
6. Remove the gasket and clean the gasket housing through the locating dowel pin. 8
seating area. mounting bolts coupling cover and housing
must be tightened to specified torque with
7. Carefully remove the friction disc and
17mm socket and 5 mounting bolts coupling
intermediate plate from the brake housing and
cover & housing to bull cage with 19mm
mark it immediately.
socket.
Note : Dismantle the parking brake linkages prior to
11. Fit the swing arrestor sub assembly along
dismantling the service brakes.
with the plunger spring and 2 copper washers.
Turnbuckle 12. The brake lever outside on the cross shaft
Brake Pedal and lock it with the circlip.
Pedal Return 13. Connect the brake pedal and brake lever with
Spring the turnbuckcle without any preloading.
14. Fit the pedal return springs with the
Pedal Cross corresponding pedals lh & rh.
Shaft
C) BRAKE STANDARD OPERATING PROCEDURE

1. Assemble the brakes and swing arrestor as
Fig. - 3 per the brake fitment procedure andconnect
B) BRAKE FITMENT PROCEDURE the brake linkages from brake lever outside
1. Fit the brake housing onto the bull cage with to the brake pedal without any preload.
207
the help of locating dowel pin (fig-4) 2. Loosen the turnbuckle lock nuts A & B and
2. Tighten the 2 mounting bolts with 19mm adjust the pedal free play for a pedal travel
socket onto the bull cage. of 90mm at the pedal (fig-6). Then tighten the
lock nuts A & B (fig-5).
3. Fit the oil drain plug on the bottom of brake
housing both lh & rh. Turnbuckle
4. Connect the oil inlet pipes onto the brake connected to brake
lever outside
housing. Lock Nuts A&B
Dowel Pin Dowel Hole
Brake Pedal
Brake Pedal
Return Spring
Turnbuckle linked
to brake pedal
Fig. - 5
Fig. - 4

Fig. - 1
208
Fig-2 - OIL IMMERSED BRAKES - EXPLODED VIEW

3. Repeat the same for lh brake and ensure both 6. Intermidiate plate & return spring of actuating
the brake pedal are in equal height. assembly should be replaced during
4. Drive the tractor in high reverse gear in pedal replacement of liners.
latched condition & apply panic brake brake 7. Brake adjustment should be done as per the
to butt the actuating discs with brake housing sop.
at bottom side. This ensures propeer 8. Ensure that the friction discs slide freely on
adjustment of adjuster plunger automatically. the splined shaft.
5. Loosen the turnbuckle lock nuts A & B and 9. In every brake overhauling replace
adjust the brake pedal travel to 65 mm and
10. Replace gasket between end cover and
tighten the lock nuts.
housing
6. Carry on the road test and check for straight
11. Replace diff lock oil seal
line braking and any other abnormalities.
12. Replace copper gasket & plunger spring of
7. In case of any abnormalities like brake
swing arrestor
jamming, dragging, jerking and pedal going
down, remove the swing arrestor sub assy 13. Remove the swing arrestor & reset the
and reset the plunger as per the reseting plunger.
procedure and fit the swing arrestor sub assy 14. Ensure proper sealing
back onto the brake housing and repeat the 15. Brake adjustment should be done as per the
procedure 2 to 6. sop.
8. During brake setting hand brake must not be 16. Friction liners once removed from the pack
in ‘on; condition. has to be coated with recommended rust
inhibiting oil.
DON’T’S :
1. Do not use non-recommended grade of oil.
2. Do not adjust the brake linkages for a pedal
travel less than 65mm.
Fig. - 6 Fig-7 3. Avoid cleaning or degreasing of friction liners
with chemical agents or acids.
DO’S & DON’T’S OF WET BRAKE WITH SWING
4. Do not use non recommended grade of liners.
ARRESTOR
5. Automatic swing arrestor should not be
DO’S :
adjusted or removed during any time other
1. Ensure proper quantity of oil in the than brake liner replacement.
transmission.
6. Donot remove the adjuster plunger from
209
2. Proper grade of oil (TRACT ELF MM) must swing arrestor sub assy. Without the re-setting
be used. tool.
3. Friction liners to be changed when the
thickness becomes 4.15mm and less. PRECAUTIONS:
4. Lined friction disc to be handled with care to 1. Ensure proper sealing to avoid water entry.
avoid damage to liners. 2. Oil level to be checked maintained as per the
5. New friction disc must be soaked for recommeded quantity on weekly basis.
minimum of one hour on the recommened 3. Always maintain 65 mm padel free play
grade of oil before fitment. 4. Brakes must not be used in engine off
condition (towing application)

AUTO ADJUSTER ASSY - PARTS
Fig. - 8
AUTO ADJUSTER ASSY – TEETH PROFILE
Fig. - 9
AUTO ADJUSTER ASSY – PLUNGER RESETING
210
Fig. - 10

GROUP - 9
Steering
Mechanical Steering
Rane Madras Ltd.
• Description
• Removal
• Dismantling
• Cleaning, Inspection & Repair
• Assembly
• Installation
ZF Steering
• Construction
• Adjustments
XLO Steering
• Inspection & Servicing
• Backlash Adjustment

Steering
STEERING-MECHANISM
RANE MADRAS LTD.
Fig. 1
212
1. Nut main 12. Plate cover 23. Oil seal
2. Tube transfer 13. Plug 24. Felt
3. Retainer 14. Ball race adjustable 25. Lock washer
4. Column inner 15. Race inner 26. Lock washer
5. Bolt 16. Roller spherical 27. Ball race
6. Ball 5/16” 17. Shaft rocker 28. Adjusting screw
7. Box cpte 18. Column outer 29. Shims
8. Bush 19. Bush rubber 30. Gasket
9. Bolt 20. Bush nylon 31. Drop arm
10. Bolt 21. Nut lock
11. Pin dowel 22. Nut

Steering
1. DESCRIPTION
(a) Mechanical Steering
The recirculating ball type steering gear is totally
enclosed in a malleable iron box and steel tube,
the latter encloses the inner column steering
shaft. It is supported by a bush assembly at the
upper end of the steering shaft which serves as
the cam/ worm gear and is supported by ball
race, inner race and 13 steel balls either side of
the camshaft assembly. A rocker shaft is set at
90 to the cam and supported by three replaceable
bushings. The outer end of the rocker shaft is
splinel to accept the drop arm which is retained
by a nut and lock washer. The steering wheel is
keyed to the steering shaft and is retained by a
nut. To remove the steering wheel use special
service tool MST-H1/2-CH-2 (fig. 1a & 1b) as
follows:
Remove cap and lock nut of the steering
wheel.
The ‘C’ clamp of the tool is placed behind the
steering wheel.
Place the 3-bolt assembly of the toolon top
Fig. 2
of the steering wheel hub and screw the ‘C’
clamp such that centre bolt of the tool rests
over the steering column. The complete assembly is dowelled and bolted
On tightening centre bolt and the nut to the upper machined surface of the clutch
assembly, steering wheel can be removed. housing. The rocker shaft disrotated as the main
nut assembly moves up and down the inner
steering column, the main nut assy. (1-1) consists
of (6,2,3,5-1). Turning the steering wheel in either
Fig. 1a
213
Fig. 3
direction moves the main nut up and down the

inner steering column assembly. A log on the main
nut engages a helical groove in the rocker shaft
assembly arm, (34-1).
Fig. 1b

Steering
Fig. 4
Fig. 8
2. REMOVAL
(a) The Steering Box
1. Remove the instrument panel as detailed in
ELECTRICAL & INSTRUMENTS.
2. Remove the fuel tank and rear support as
detailed in FUEL SYSTEM.
3. Disconnect the drag link from the drop arm
as detailed in AXLES AND WHEELS.
4. Remove the four securing capscrews (1-2) nut
and lockwasher (2-2). Then lift the steering
box assembly (4-2) and clear off the clutch
housing.
3. DISMANTLING
1. Remove nut (5-2) securing the drop arm (6-2) from
the rocker shaft. Remove drop arm using a special
service tool MST-H1-CH-3 (fig 8a & 8b)
Fig. 6
Fig. 8a
214
Fig. 8b
Fig. 7

Steering
NOTE : The drop arm must not be hammered from

the rocker shaft as serious damage to the
cam may result.
2. Drain oil from the steering gear.
NOTE : Before removing the drop arm, punch mark
the drop arm and rocker shaft to ensure that
the drop arm is installed on the same
serrations.
3. Remove bolts securing the cover plate (9-1).
Remove the cover (12-1) plate and pull out the
rocker shaft. Collect spherical roller balls (fig.3).
4. Remove the bolts and spring washers securing
the outer column (18-1). Slide out the outer
column and collect the shims (33-1). Fig. 9
5. Position the main nut (2-4) at the centre of the

worm (1-4) and lift the inner column assembly
(3-4). Collect top (1-8) ball race (2-8) and steel
balls (13) carefully.
6. Draw out the inner column through the side cover
opening. (See Fig. 7).
7. Collect the ball race, inner race and (13) steel
balls carefully from bottom.
8. Remove main nut (2-4) from the inner column
Fig. 10
(3-4). Carefully collect 27 nos. steel balls.
9. Remove oil seal (23-1) from the box casting by 3. Examine the steel balls and ball races for
levering at diametrically opposite points. grooving, pitting or uneven wear. In case the steel
(b) The Drag Link balls are damaged, replace the entire set of balls
after ensuring no damage to races. Also if the
(1) Slacken the two locknuts and unscrew the
races are damaged replace them along with the
both ball and joints.
steel balls.
(c) The Tie Rod
4. Check fit of inner column upper bearing area in
(1) Slacken the lock nut and remove the upper bush. If a slack fit is apparent renew the
adjustable ball end joint LH and then remove bush. It is adviceable to replace the rubber bush
the adjustable ball end joint L.H. and then while replacing the bush.
remove the pinch bolt and withdraw the track
5. Check the rocker shaft bush in the box bore. If
adjuster end RH.
a slack fit is apparent the bush should be
4. INSPECTION OF DISMANTLED PARTS renewed.
1. Examine the steel balls and bearing tracks of main 6. In case of accident damage and also during
nut and inner column. If damage to either regular overhaul the inner and outer columns 215
component in the form of grooving or pitting is should be checked for bending.
evident, the inner column and main nut assembly
Support inner column on two V blocks one at top
must be renewed as a set.
column bush area and one at worm. Dial the run
2. Examine the rocker shaft barrel and conical faces out reading at the bearing area of worm (max
for uneven or excessive wear or pitting marks. permissible 0.13 mm) and at the center (max
Check the splines for any twist or damage. Check permissible 1 mm). (Refer para 6 service
the spherical roller bore in the shaft for uneven informations).
wear or pitting. If any of the above mentioned
NOTE : In the interest of safety and reliability all
defects is noticed, the rocker shaft is to be
steering gear components must be in good
replaced.
condition.

Steering
Fig. 11
Fig. 15
5. ASSEMBLY
(a) 1. Clean all components before use.
2. Ensure that the transfer tube retainer bolts
are fully tightened and the retainer strap
corners are bent to lock bolts, if they are
removed for any reason.
3. Smear grease on main nut track (See Fig.
3) (use shell Donex Retinax RB Grease) and
place the steel balls (8mm dia.) on the track
and through the transfer tube. (Ensure
number of steel balls : 27). Screw the main
nut assembly on to the helix of the inner
Fig. 12
column. (Fig. 4).
4. Tap the adjustable ball race in position in the
bottom bore, smear grease and arrange
13 steel balls (7mm dia) around it’s track.
(Fig. 5).
5. Slide the inner race to the bottom bearing
zone of inner column. (Fig. 6)
6. Screw the main nut assembly approximately
midway on the helix. Smear grease on upper
bearing zone of the inner column. Place
Nyloncage steel balls (7mm.) around the top
bearing zone of the inner column. Insert the
inner column and main nut assembly in to the
case through the side opening and allow the
inner column to rest on the steel balls on the
Fig. 13
lower adjustable ball race. (Fig. 7).
7. Slide the adjustable ball race through the inner
216
column carefully into the box. Ensure that all
the steel balls are in position. (Fig. 8).
8. Fit new paper gasket on the box face
applying thin coat of shellac. (Place the
original pack of shims). Fit a new paper joint
on the outer column face. Slide the outer
column assembly and tighten the tube
housing bolts to the correct torque. (Fig. 9
& 10).
NOTE : Do not torque the outer column pedestal
Fig. 14 mounting bolts immediately. Rotate column

Steering
CAUTION :
14. Set the steering gear to mid gear position
(i.e.) half the number of turns from lock to
lock.
15. Assemble the lock nut to the adjuster. Drive
the adjuster and lock nut assembly to the
cover plate, until it just butts against the
rocker shaft to eliminate rocker shaft end float
at mid gear position. On achieving this
condition tighten the adjuster further until
required preload is established. Lock the
Fig. 16 adjuster with lock nut. Ensure no torquing is
done on the adjuster.
assembly while tightening the bolts, to prevent
jamming the bearings if the initial amount of NOTE : It is important to observe the mid gear
shims are inadequate. position (MGP) since the gear is designed to
give more backlash at the extreme lock
9. Temporarily fit the steering wheel. Check
positions than is present in the mid gear
preload using a spring balance fixed to
position, Therefore, if end float adjustment is
steering wheel rim or alternatively as shown
carried out with the steering gear in lock
in the figure 11.
positions, severe binding would occur when
NOTE : Ensure that only one steel ball moves with in mid gear position.
hand pressure in upper and lower ball races.
16. Drive a new rocker shaft oil seal into the oil
To check this condition thrust a steel poker
seal bore in the box using suitable mandrel.
(Fig. 16).
17. Mount the steering gear on the vehicle.
18. Install the steering wheel and secure it by the
retainer nut.
19. Ensure that the steering gear assembly is
filled with correct grade and quantity of oil.
Fig. 17
20. Install the drop arm 34-1 to the rocker shaft.
in between the steel balls. (Fig.12).
NOTE : The rocker shaft and drop arm have four
10. Until the correct preload is established add master splines order to assist correct
or remove shims. assembly. Ensure the punch marks made
11. Slide the spherical roller on the machined stub during dismantling are aligned.
of main nut. (Fig.13). 21. Install the lock washer and securing nut and
12. Slide the rocker shaft into the case so torque 115 Nm.
that its bore slides over the spherical roller. 22. Install governor control linkage.
(Fig. 14).
(b) The Drag Link 217
13. Place a joint washer on the cover plate
1. Assembly is the reversal of the dismantling
mating face of the box casting applying
procedure.
shellac. Fix the cover plate in position.
Tighten the bolts to the correct torque. (c) The Tie Rod
1. Assembly is the reversal of the dismantling
procedure.
6. SERVICE INFORMATION
During regular servicing of Steering Gear and in
case of accident, check the following in addition
to other features.
Fig. 18 (a) Inner column run-out Support Inner column on

Steering
suitable ‘V’ blocks as shown at places A & B between steering knuckle and drop arm
(Fig.17). centre.
Run out at C & D should be within 0.13mm (Total 5. Move the drop arm forward 8mm and connect
indicated reading). and tighten the drag link ball joint to the drop
Run out at E should be within 1.0 mm (Total arm.
indicated reading). NOTE : The above method prevents steering box
(b) Outer column flange squareness with respect to components fouling when the drop arm is in
tube outer dia. (Fig.18) the maximum backward position the forward
condition should be automatically but must
Support outer tube on ‘V’ blocks as shown
be checked as follows.
Face out of flange should be within 0.1mm (Total
Set the front axle to maximum track fully left
indicated reading).
hand lock and maximum downward tilt of the
1. Since these are critical components do not left hand road wheel.
try straightening if bent excessively.
The left hand road should be hard against
2. Ensure that the steering column is not the wheel stop if the drag link is disconnected
strained while fitting any bracket. from the drop arm further forward movement
7. INSTALLATION of the drop arm should be possible.
(a) 1. Install the steering box onto the two locating (b) The Tie Rod
dowels on the machined face of the clutch Adjustment of the tie rod length is to give correct
housing and secure with four cap screws. ‘Toe in’ is fully described in AXLES AND
2. Install the fuel tank and rear support as WHEELS.
detailed in FUEL SYSTEM.
SERVICE INFORMATION
3. Install the fuel panel as detailed in
ELECTRICAL & INSTRUMENTS. During regular servicing of Steering Gear and in case
of accident vehicles check the following in addition
(b) The Tie Rod
to other features.
1. Installation is the reverse of removal
(a) Inner column run-out
procedure. Refer to adjustment in AXLES
&WHEELS. (Group 5 chapter 3) Support Inner column on suitable ‘V’ blocks as shown
at places A & B.
8. ADJUSTMENTS
Run out at. C & D should be within 0.13 mm (Total
(a) 1. After adjusting the toe in set the front wheel
indicated reading).
to minimum track and turn the wheels to full
right hand lock. They center the steering Run out at E should be within 1 .0 mm (Total indicated
linkage the tractor will turn at equal angles reading).
both left and right. (b) Outer column flange Squareness with respect
NOTE : It is most important that the steering linkage to tube outer dia.
be set centered. Support outer tube on ‘V blocks as shown:
2. Move the steering drop arm to the maximum Face out of flange should be within 0.1 mm (Total
backward position. This can be readily indicated reading).
218
established as the steering box main nut stop CAUTION :
against the end of the worm helix and
1. Since these are critical components do not try
consequently no further backward movement
straightening if bent excessively.
of the drop arm will be possible.
2. Ensure that the steering column is not strained
3. Maintaining the above position, connect the
while fitting any bracket.
drag link to the steering kunokle arm and
fighter to the torque specified. Refer to
specifications Para 2 AXLES AND WHEELS.
(Group 5 chapter 3)
4. Adjust the drag link length between ball joint
centres to 8mm shorter than the distance

Steering
ZF - STEERING GEAR mechanical damage to the steering gear box

may occur.
Construction :
The basic Steering gear consists of a Worm & Roller Adjustments :
assembly housed in a cast iron housing. The Worm 1. Play in the Worm bearing :
is welded on the solid Steering column (inner column). For reducing the play :
The upper end of the inner column is enclosed by a Reduce the number of shims between the bottom
hollow jacket tube (Outer column). A rubber bush flange and the housing till the desired play is
holds the upper end of the steering inner column in achieved i.e. the Worm rotates neither too freely
a coaxial position with respect to the outer column. not too tightly. Jamking of the ball bearings will
The lower end of the steering inner column is reduce their life.
supported in the steering housing by a set of ball cage
For Increasing the play :
on either side of the Worm. The Bearing races for the
set of abll cages are press fitted in the steering Increase the no. of shims between the flange and
housing. the housing.
The lower end of the steering housing is closed by Permissible play in worm bearings is
0.22 Nm - 0.56 Nm (Torque at worm and column
an adjusted by removing or adding these shims. The
assembly)
sector shaft has a roller assembly on one end &
serrations for carrying the steering drop arm on the 2. Play between Worm & Steering Roller Shaft :
other. The roller of the sector shaft is always in mesh For Adjusting the end play between Worm &
with the Worm. The drop arm side of the shaft is Steering Roller Shaft :
supported on two bearing bushes while other side is • Bring the steering to straight ahead psostion.
supported in a housing cover throught another bush.
• Loosen the lock nut over the play adjusting
The housing cover carries the end play adjusting screw on the housing cover.
screw.
• Turn the adjusting screw in till the play
The steering housing is sealed to prevent oil leakage reduces. The play can be checked by pulling
by providing : the drop arm back & forth.
• Gasket between the housing & housing cover • Turn the Steering Wheel quickly from one
• An oil seal on the sector shaft side just side to the other. In the middle range a slight
before the drop arm resistance should just be felt then steering
wheel is turned with one finger. A tight
Mounting the drop arm : adjustment, rather than improving steering
While mounting the steering drop arm on the sector ability, reduces efficiency & life of the steering
shaft, the position of drop arm relative to the shfat gear.
is vital. Usually a marking is given both on the drop
arm & on the sector shaft. While fitting the drop arm
ensure that these two marks coincide. However if there XLO STEERING
are no markings on either drop arm or sector shaft A) INSPECTION AND SERVICING / ADJUSTMENT
then following method should be adopted : PROCEDURE FOR XLO STEERING
• Bring steering to straight ahead position 1. Inspection & Servicing / Adjustment Procedure
219
• Bring the wheels also as close as possible Checkpoint
to straight ahead position A) Check For Clamping / Tightening
• Connect the drag link to L.H. steering arm 1 Mounting bolts of strg. Assy
• The drop arm can then be placed (by means 2 Shaft nut of Drop arm
of it’s spline) in required position on the 3 Nuts of drag link’s ball-joint
steering sector shaft. 4 Wheel-nut of strg. Wheel
• Ensure that on turning the steering fully to B) Check oil level in the strg. gear assy.
the right and to the left, the stopper on the C) Check the free play on strg. Wheel
steering knuckle touches the stopper on the 1 Keep both the front wheels in SAP (Straight
axle. If not, adjust the drag link length till it Ahead Position) and check the free-play at
does so. If this is not ensured then serious the steering wheel

Steering
2 The free-play value should be minimum in
SAP and slightly more in other position than
SAP
D) Check complete assembly for oil-leakage, if minor
seepages observed :
1. From adjusting screw Nut (opposite to Drop
arm)
2. Shaft cover screws
Procedure for servicing / Adjustment

A) If found loose, tighten them properly
B) If oil level is less, fill the oil SAE 140 upto maximum
level, and tighten the oil filler plug.
C) 1 If it is more than normal it should be
adjusted as per “Blacklash adjustments”
procedure enclosed
2 It it is moe in SAP than other position it
should be adjusted as per “backlash
adjustment” procedure enclosed
D) 1. Replace rubber ‘O’ ring by holding adjusting
screw in same position and tighten the screw
2. Apply Thread sealent or Teflon tape & tighten
the screw
BACKLASH ADJUSTMENT PROCEDURE FOR XLO

STEERING GEAR ASSEMBLY
Procedure :
1) Bring the tractor in S.A.P position i.e. keep
both the fron wheels in straight-Ahead
position.
2) Mark a line on jacket tube and strg. Wheel
in above condition by chalk, this is Mid-gear
position of stg. Assy.
3) Remove drag-link connections from the Drop
arm of steering gear assembly.
4) Check backlash on Drop arm by hand in
S.A.P if it is more than 0.5mm appx. at the
end of Drop arm, then do the adjustment as
mentioned in point 5 & onwards.
Note : Backlash to be checked in mid-gear position
220 of steering gear assembly, i.e. by matching
initial markings of jacket tube and steering
wheel as per point no. 2
5) Loosen the lock nut of adjusting screw of
gear shaft and keep the steering wheel
rotating approx. 1/4 turns clock-wise and anti-
clockwise direction and turn the adjusting
screw clock-wise, until and slight drag can
be felt on streering wheel across the centre.
Now hold adjusting screw in position and
tighten the lock nut.

GROUP - 10
Instruments, Gauges & Electricals
Instruments & Gauges
Testing of Instruments
Lighting System
Trouble Shooting
1st Version 4th set.pmd 221 6/3/2006, 11:17 AM

A. INSTRUMENTS & GAUGES (Sarpanch) 3. AMMETER

This instrument is held in position on the panel
by a ‘U type instrument clip. An ‘O’ ring seals the
exterior fit of the instrument on to the panel.
The instrument is of the normal centre ‘O’ type
with a side deflection of 30 amps, it indicates
charge or discharge or no current flow in Battery/
Alternator circuit. When Alternator output is
sufficient Ammeter will record a charge; when
battery voltage exceeds Alternator voltage, the
Ammeter will show a discharge; with voltages
equalised and no current demand, or when
Alternator is stationary or cut-out is open and no
load is applied the Ammeter will read ‘0’.
If it shows discharge at any time, investigate the
Fig. 1 - Instrument Panel (Sarpanch)
cause to avoid battery discharge and damage to
1. Governor Control Lever 9. Starter Switch
the Alternator.
(Throttle) 10. Hazard Switch
2. Water Temperature 11. Pull to Stop Knob 4. FUSE BOX
Gauge in 0F 12. Tachometer cum The fuse box that is located below the battery
3. Brake Light Indicator Hour Meter contains five fuses for seperate electrical circuits.
4. Oil Pressure 13. Light Switch If a short circuit occurs the fuse burns out, the
Gauge in lbs/in2 14. Ammeter circuit is broken and damage to the electrical
5. Horn Button 15. Battery Indicator
system is prevented. It is very easy to
6. Side Indicator Rotary Switch 16. Fuel level Gauge
investigate the electrical fault. If any electrical
7. Plough Lamp Rotary Switch 17. Direction
system fails check the fuse. If the same fuse
8. Gear Shifter Lever Indicator Signal
frequently burns out, check the particular electrical
1. HEAT INDICATOR / WATER TEMPERATURE circuit.
GAUGE 5. LIGHT SWITCH
The heat indicator is held to the panel by an ‘O’ The “off” position should be listed.
type instrument clip at the rear and is weather It is a four position switch with the following
sealed by an ‘O’ ring on the exterior. clockwise movement.
The face of the indicator shows a scale divided 1. Operates the gauge lamps, side, panel and
into three sections, White, Green, and Red in tail lamps.
colour to denote Cold, Run and Hot temperatures. 2. Side, panel tail and dipped head lamps, main
The engine should be run with the indicator needle beam.
on the green - thus indicating the optimum engine 3. Side, panel, tail and head lamp main beam.
operating temperature. Do not work, the tractor 4. Head lamp main beam only.
with the indicator in the red section.
6. RPM CUM HOUR METER
The gauge end of heat indicator is connected by
This instrument records the approximate Engine
a totally sealed tube to a thermal bulb screwed
Hours run as well as showing the engine
into the water jacket on the left hand side of the
revolutions per minute and P.T.O. speed.
cylinder head.
It is fitted to a special mounting bracket below
222 2. HORN BUTTON the instrument panel. It is operated by a flexible
drive from the oil pump drive shaft on the right
The horn button is located to the lower R.H.
side of the crankcase.
corner of the instrument panel. It is secured by
a nut on the inner edge and has both on outer (a) Removal
and an inner securing washer. (1) Remove the four screws holding the
tractormeter mounting bracket to the
The horn itself is positioned on a bracket forward
instrument panel and lift the bracket away
of the radiator.
from the panel.

(2) Unscrew the knurled nut from the center of (5) Replace the mounting bracket onto the
the tractormeter. instrument panel.
7. OIL PRESSURE GAUGE
This is held to the instrument panel by an U type
mounted bracket below the instrument panel.
The pressure line runs from the instrument to an
elbow tapped into the oil gallery at the right hand
side of the crankcase.
The face of the gauge is divided into segments
— red and green. At correct oil pressure the
indicator needle should be central in the green
segment. This shows that oil is circulating at the
correct pressure through the engine.
The engine should not be run if the needle is
Fig. 2 - Oil Pressure line Elbow continually in the red zone.
(3) Remove the two knurled nuts holding the 8. PLOW LAMP SWITCH
retainer to the back of the hourmeter and lift The plow lamp/rear work light is mounted on the
off the retainer. right fender; the lamp switch is mounted on the
(4) The hourmeter can now be lifted from the instrument panel below the water temperature
front of the bracket. gauge.
(b) Removing the Flexible Drive 9. TURN SIGNAL SWITCH
(1) Remove the mounting bracket from the (SIDE INDICATOR ROTARY SWITCH)
instrument panel and unscrew the knurled nut The turn signal switch is mounted on the
on the drive end cable. instrument panel below the temperature gauge.
(2) Tie a length of string to the flexible drive to Moving the switch to the right causes the right
facilitate re-threading the cable. signal lights to flash, indicating a right turn;
(3) From the left hand side of the tractor below moving the switch to the left causes the left signal
the scuttle pull the flexible drive down through lights to flash, indicating a left turn. Moving the
the steering column tunnel in the fuel tank. switch to the center position extinguishes the
Undo the string at this point. lights.
(4) Thread the cable through the grommet in the 10. TURN SIGNAL INDICATOR LIGHT
fuel tank support and across to the right hand The turn signal indicator light is located above the
side of the tractor. turn signal switch and between the oil and
(5) Unscrew the two capscrew at the drive end temperature gauges. It shows the operator which
and remove the drive cable. turn signal is actuated.
(c) Replacing the flexible hourmeter cable 11. BATTERY INDICATOR WARNING LIGHT
(1) Thread the drive across from right to left of The battery indicator warning light is located on
the tractor, through the grommet to the left the top left of the instrument panel between the
of the fuel tank support. ammeter and fuel level gauges. When the starter
switch is turned to the on position before the
(2) Attach the string to the drive cable below the engine is started, the light should glow brightly;
knurled nut and pull the drive up through the if the light doesn’t glow, the alternator will not
steering column tunnel. charge. When the engine is running, the light
(3) Fit the drive end outer flange of the inner should go out. If the light doesn’t go out, it 223
cable into the housing at oil pump press fully indicates the alternator isn’t charging the battery.
home and screw the 2 cap-screw. It may be 12. FUEL GAUGE
necessary to turn the inner cable to allow it
When the starter switch is turned to the on
to take proper place.
position, the fuel gauge will indicate the level of
(4) Fit the tractormeter end of the cable into the fuel in the fuel tank. The sender is located under
tractormeter and replace the knurled nut. the cover on top of the fuel tank.
Remove the string.

13. BRAKE LIGHT INDICATOR Procedure for replacing child parts of NST
The brake light indicator is located at the top right Instrument Panel
of the instrument panel between the temperature 1. Open the Scuttle Flapper.
and oil pressure gauges. The light will glow when 2. Disconnect the Hourmeter cable from the
the starter switch is turned to the run position if
Hourmeter by loosening the Knurling nut. Also
the parking to release it before driving off.
disconnect the pipe connecting the Oil pressure
14. HAZARD WARNING LIGHT SWITCH gauge by removing the nut.
The hazard warning light switch is located below 3. Remove the Scuttle Assembly Panel and
the instrument panel next to the starter switch. disconnect the Wiring harness connector of the
It is advised that the hazard warning lights be used Instrument Cluster.
whenever the tractor is operated, parked or towed
on public roads day or night. It is also required 4. Unscrew 5 Screws of the Instrument Cluster
by law in many locals to use a Slow Moving Front Panel.
Vehicle (SMV) emblem for any operation on public 5. Remove the Instrument Cluster from the
roads. dashboard.
15. STARTER SWITCH 6. Unscrew the 4 screws of the back cover.
This starter switch performs the following functions 7. Bulb holders are snugly fitted into the Assembly
in each position as noted : Case and can be removed by pulling out.
1. OFF - All electrical equipment is turned off Always hold the bulb holder at the base to
in this position. prevent strain on the wire (Fig. 7).
2. RUN - All instruments, gauges, warning lights 8. Individual Gauges can be removed by
and the charging circuit receive power in this unscrewing the screws once the coupler are
position. disconnected.
3. START - Engages the starter to start the 9. While refitting the gauges always connect the
engine. This is a spring loaded, “momentary wires as per indications given in the Assembly
contact” position and should be released as case and the Wiring diagram given below.
soon as the engine starts to avoid starter
damage.
B. INSTRUMENT PANEL (NST)
The various instrument gauges and switches are
mounted on the instrument panel.
The pannel which is secured by four screws on the
fuel tank under the steering wheel. The operator can
easily pay attention to the gauges and Indicators and
he can reach to operate the switches while driving.
224
Fig. 3. - NST Instrument Panel
1. Panel Instrument Complete
2. Gauge Voltmeter Assembly
3. Gauge Fuel Assembly
4. Gauge Temperature Assembly
5. Gauge Oil Pressure Assembly
6. Gauge Hour Cum RPM Meter Assembly Fig. 4. - Wiring diagram NST Instrument Panel

Moving the lever counter clockwise from the

neutral position will “ON” the LH indicator.
Turn signal light is operational in both movements
of combination switch lever (upward & downward
direction).
c) Horn signal
Pressing the end knob inwards on the combination
switch lever will activate horn.
Fig. 5 - Back side of Instrument Pannel (Assembly case)
(C) INSTRUMENT PANEL (BHOOMIPUTRA)
1 2 3 4 5
13 6
12
7
11 10 9 8
Fig. 8. - Instrument Panel (Bhoomiputra)
Fig. 6 - Back side of Instrument Pannel (Assembly case) 1.Temperature Gauge 8. Starter Switch
2. Voltmeter 9. Hazard Warning Switch
3. Dashboard Panel 10. Dashboard Plate
4. Head Light Switch 11. Hourmeter
5. Plough Lamp Switch 12. Oil Pressure Gauge
6. Turn Signal Switch 13. Fuel Gauge
7. Horn Switch
Procedure for Replacing Indivudual Parts :

1. Detach the dashboard plate from the dashboard
panel unscrew the 4 mounting screws.
2. Detach the dashboard panel from the tractor
after unscrewing the 4 mounting screws.
3. Remove the wiring harness coupler from the
Fig. 7 - Replacement of Bulb main wiring harness.
4. Remove the hour meter cable of the Hourmeter
1. COMBINATION SWITCH (FOR NST) by unscrewing the nut of the Hourmeter cable.
Combination switch is mounted on LH side of 5. Remove the oil pressure pipe from the oil
steering column. It is a single lever switch pressure gauge by removing the Hex. Nut
performing 3 different operations. 6. Remove the respective couplers from the
a) Hi-Low beam switch : switches.
1. For operating high (main) beam the 7. Remove the instrument cluster from the
dashboard panel by unscrewing the six screws
multiposition light switch on the scuttle panel
on the backside of Instrument assembly
must be in third position and the combination
switch lever in downward direction. 8. Remove the wires from the terminal of the
electrical gauges. 225
2. For operating low (dipper) beam the
multiposition light switch on the scuttle panel 9. Unscrew the individual gauges
must be in third position and the combination 10. Remove the crystal ( glass ) gently.
switch lever in upward direction. 11. Remove the black facia.
b) Turn signal : 12. Remove the defective meter & replace it with
Moving the lever clockwise from neutral position a new one.
will “ON” the RH indicator. 13. Follow reverse procedure for assembly.

(D) BATTERY (d) Dip the sensor in hot/boiling water.

In general the battery is placed into the system (e) Measure the temperature simultaneously by
to supply cranking current to the starter motor and a thermometer.
excite the electrical system. This battery is (f) Check the gauge pointer position.
charged by the alternator.
(g) The green zone of the gauge is between 60º
& 103ºc, ± 3ºc.
1 (h) If the gauge does not show any deflection of
pointer/nedle then there is a possibility that
either sensor or gauge is difective.
(i) Replace the sensor and again check as per
d.e.f.g.h. above.
(j) If gauge shows the correct reading then
sensor is defective, if not, the gauge is
defective.
(k) Replace the defective parts & connect the
wiring circuit.
Fig. 9
Fig. 11
2. FUEL LEVEL GAUGE

(a) Remove the tank unit coupler. The needle at
gauge should show full.
(b) Short the two terminals of the gauge
connector with a piece of wire. If the gauge
is “OK” if will show ‘Empty’ position. If
doesn’t Replace the gauge. If the gauge is
Fig. 10
found ok, wiring & tank unit should be
1. Removal checked.
(a) Remove the screws (1-1) and pull out the (c) Checking of the fuel gauge ‘Tank unit’ as
grille. follows.
(b) Remove the positive and negative cable. (1) Remove the Tank unit from the fuel tank
by removing six screws and spring washer.
(c) Open the wing nuts on studs and pull out the
clamping strip. NOTE : Care should be taken to match the arrow and
pin on the gauge unite with the hole on the
(d) Lift battery from the carrier.
fuel tank.
2. Installation
(2) Connect the tank unit as shown in the
Reverse the procedure of Removal. circuit diagram. Move the float of the tank
unit from down to up ward by hand. If the
(E) TESTING OF INSTRUMENT needle/pointer of gauge moves from minimum
1. HEAT INDICATOR / WATER TEMPERATURE to maximum position the tank unit is ‘ok’.
226
GAUGE.
(a) Refer b. 1 to 5.
(b) Remove 3 screws with cables of temperature
gauge and take out gauge unit. And sensor
which is fitted on thermostat housing.
(c) Connect the gauge & sensor as shown below
in the wiring diagram. Fig. 12

3. BRAKE LIGHT SWITCH This lighting system is available as two separate

(a) Remove the connector of brake switch & attachments and can be fitted to the standard tractor
short the two terminal of the connector from without additions or modification to the existing
wiring harness side with a piece of wire. If standard wiring harness. These attachments are known
the brake light glows, the brake light switch as :-
is faulty. Replace the switch. If brake light (a) Head lamps and Plough lamp attachment
does not glow then check bulb & wiring. consisting of two head lamps, having-double
Replace the defective bulb & rectify the filament bulbs to facilitate use of head lamps in
wiring fault if any. a dipped or straight ahead position which operate
from a switches of the dashboard panels.
(2) Depress the brake pedal an check whether
the brake light glows or not. This is to confirm The head lamps are mounted to the front on the
the proper functioning of switch. If the light left and right hand side of the hood.
glows then the switch is ‘ok’ otherwise replace The plough lamp, having an adjustable mounting
the switch. Refer circuit diagram operate the to suit every working condition, is fitted to the right
Brake light switch by pulling the knob. If the hand rear wheel fender. The plough lamp is
bulb glows then the brake light switch is ‘ok’. independent of the head lamp switch on the dash
If not the switch is defective. panel. A switch the plough lamp controls the light
from separate switch on the dash panel right hand
side.
(b) Road Traffic Regulation Lighting attachment
consists of a combined side and rear lights and
separate reflectors mounted on the left and right
hand rear wheel fenders. The side and rear lights
are operated from the head light switch situated
Fig. 13 on the left side of the panel and turn signal switch
4. HORN BUTTON is provided on the right side.
A registration plate light and power socket plug
(a) Disconnect the oneway connection (2 nos.)
for attaching an extension lead to a trailer’ lamp
connect the 45w bulb to these terminals as
or inspection lamp are also provided. The power
shown in diagram below.
socket plug is situated to the left hand rear side
(b) Press the button if the bulb glows the horn of the registration plate. The registration plate light
push button is ok. If not check the wiring & and power plug are operated from the side-light
rectify the wiring if any fault is observed. switch.
(c) After rectifing the wiring fault repeat step b, An electric horn, operated by push button on the
if the bulb glows push button is ok. If not dash panel, is situated on the bolster support.
Replace the push button. 2. CHECKING LIGHTING SYSTEM FAILURES
(d) If the Horn does not sound even after Failure of the lighting system in part or in whole
replacing the push button. Horn need to be can be attributed to various points in the system
checked. which can only be found by a process of
elimination.
By making reference to the wiring diagram the
following points should be checked when
investigating failures to the lighting system.
1. Control Switches
2. Fuse—Open circuits
3. Earth Contacts
Fig. 14 4. Loose connections or broken wires
5. Bulbs — burnt out or not making contact
THE LIGHTING SYSTEM 227
6. Battery conditions
1. DESCRIPTION
3. REMOVAL AND DISASSEMBLY
In addition to the standard electrical system fitted to
(a) Head lamps Outside Grill
the tractor consisting of a alternator, voltage control,
batteries, and starting system which have been (i) Disconnect battery earth cable.
covered in the preceding paragraphs, there is also (ii) Remove the lamp rim complete with reflector
available a complete and comprehensive lighting and bulb assembly from head-lamp body by
system for every working condition. loosening locking screw and disconnecting

leads from bulb and earth terminals. (c) Side Lights/Turn Signal Lights
(iii) Loosen the cable retainer inside head-lamp (i) Disconnect battery earth cable.
body. (ii) Remove cable/adapter retaining thumb-screw
(iv) Remove the Lock nut from inside the hood from sidelight mounting stud beneath wheel
sheet securing the lamp mounting bracket to fender. Cable and adapter can now be
the hood sheet metal. removed from underside of side light.
(v) Lamp body and mounting bracket can now be (iii) Remove locknut and washer locking mounting
removed from hood, allowing the leads to slip stud to wheel fender.
through the lamp hollow mounting stud. (iv) Lift off side light.
(vi) The bulb holder may be removed by levering (v) To remove front and rear lenses loosen the
back the two spring clips hinged to the screws on top of the lamp and try open front
reflector body. or rear section of the lamp with a screw driver.
(vii) Remove the reflector by removing all spring To remove side light cable from fender
clips from inside of the lamp rim. channel proceed as for plough lamp cable.
(viii) If cable a needs replacing, disconnect the (d) Registration Light
leads from rubber covered snap clips near
(i) Disconnect battery earth cable.
“HORN” and withdraw cable from hood side
channels. (ii) Remove the two be dismantled by removing
the screw from the front centre of the lamp.
(b) Plough Lamp
(e) Power Plug
Housed in the registration plate, the plug is
(ii) Remove lamp rim/housing glass (2-15)
earthed to the lower L.H plate fixing bolt and power
reflector (6-15) and bulb (5-15) from lamp body
is supplied via the junction box.
(8-15) by loosening screw (1-15).
(f) Horn
(iii) Slip out leads from connector assy. (7-15).
(iv) Remove lock nut beneath wheel fender.
(ii) To remove horn complete, remove two cap
(v) Lamp can now be removed by lifting from
screw securing horn bracket to bolster
mounting bracket and allowing leads to slip
support.
through the lamp hallow mounting stud.
4. REASSEMBLY AND INSTALLATION
(vi) Remove bulb, connector by turning 15 from
reflector (6-15). Use reverse procedure outlined in Removal and
Disassembly.
If the plough cable needs replacing disconnect the
cable from the junction. Remove the cable clips from (a) Head lamp Adjustment
the axle, pull the cable gently from the wheel side. Face tractor up to blank wall, 15 feet away. Switch
If the complete cable needs replacing then pull entire on DIPPED head lamp beam. The top of bright
cable from the fender channel. beam spot must not be higher than 3 feet from
ground level.
I. Screw
2. Housing glass
3. Spring
4. Lense
5. Bulb
6. Reflector Assembly
7. Contact Assembly
8. Body
9. Bolt plough lamp bracket
10. Spacer
228 11. Washer plain (Nyloc)
12. Bracket plough lamp tilting
13. Nut
14. Bolt plough lamp
holding bracket
15. Washer plain
16. Cable
Fig. 15 - Plough Lamp

FRONT HARNESS FOR NST (WITH HAZARD SWITCH)
229

PLATFORM HARNESS NST
230

TROUBLE SHOOTING FLOW CHART FOR ALTERNATOR
SWITCH
IGNITION
THE FOLLOWING ARE REASONS

IF 1. FAULTY LAMP CIRCUIT
WARNING NO 2. LOOSE CONNECTIONS
LAMP 3. JAMMED/BROKEN/DIRTY BRUSHES
GLOWS 4. ROTOR OPEN/SHORT CIRCUIT
5. FAULTY ELECTRONIC REGULATOR
YES
START
THE ENGINE
THE FOLLOWING ARE
REASONS :
1. ELECTRONIC
REGULATOR FAULTY
WARNING 2. STATOR WINDING
NO CHECK AMMETER NO
LAMP OPEN/SHORT
AMMETER SHOWS
EXTINGUISHES 3. RECTIFIER BRIDGE
READING CHARGES
DEFECTIVE
4. FUSE
5. BELT LOOSE
YES YES 6. ROTOR SHORT
CIRCUIT
BUT AT
LAMP LAMP HIGH
EXTINGUISHES EXTINGUISHES SPEED
FULLY PARTIALLY
THE FOLLOWING
INCREASE FOLLOWING ARE ARE REASONS
ENGINE THE REASONS 1. STATOR ONE OR
SPEED 1. AUX. DIODE TWO PHASE
FULLY 2. STATOR FAULTY OPEN.
2. AUX. DIODE
DEFECTIVE
3. MAIN DIODE
DEFECTIVE
AMMETER
READS NO
AS PER SPEC. OVER CHARGING
OF ALTERNATOR 231
YES
ALTERNATOR 1. FAULTY REGULATOR
IS OK 2. FAULTY BATTERY

TROUBLE SHOOTING FOR STARTER MOTOR
(A) Starter does 1. Check the ignition key switch. 1. Substitute a fully charged battery.
not starts the 2. Check the battery condition. 2. Clean the battery terminal and
engine. 3. Check the proper connection apply petroleum jelly on terminal
of battery terminal. & tight all connection
4. Remove the Starter Motor. 3. Repair the Starter Motor.
(B) Starter crank 1. Check the battery condition. 1. Substitute a fully charged battery.
but engine 2. Check the fuel flow. 2. Repair fuel flow.
does not fire. 3. Remove the Starter Motor & 3. Check the defective bushes,
check. brushes, spring tension
& armature.
(C) Starter works 1. Pinion sticky on shaft. 1. Check drive movement on shaft.
but pinion fails 2. Burr on pinion / ring gear. If not OK change the drive assy.
to engage. 3. Lever defective. 2. Check the gap setting.
4. Bushes worn out. 3. Check wiring and connections.
4. Change Bushes.
(D) Starter 1. Sticky starting switch. 1. Disconnect Starter cable

continuous to 2. Sticky solenoid switch contact. immediately with battery.
run after switch 3. Pinion/Ring Gear folded or 2. Replace Starter switch.
is released damaged. 3. Deburring of Ring Gear/Pinion filling.
4. Sticky Drive Assy. 4. Check Drive Assy. movement
on shaft.
(E) Pinion engages 1. Clutch (Drive Assy.) Slip. 1. Remove the Starter and change
with Ring Gear 2. Switch defective. the Drive Assy.
but the engine 3. Check the battery condition. 2. Repair the Switch.
is not cranked 3. Replaced with charged battery.
232

GROUP - 11
Hy-Tec Hydraulics
Specifications
Principle of Operation
Removal of Hydraulic Lift Housing
Removal of Control Valve
Assembly, Installation & Adjustment
Trouble Shooting

Hy-Tec Hydraulics
234

Hy-Tec Hydraulics
235

Hy-Tec Hydraulics
SPECIFICATIONS
THE PUMP
Make : Dowty & Vickers
Type : Gear
Capacity : 12.3 cc/rev.
Output at 2100 engine RPM : 26.0 lpm
CONTROL VALVE
Make : M&M
Relief valve pressure 6000 / 5500 : 158 - 193 kg/cm2
Relief valve pressure 4500 : 140-175.8 kg/cm2
Main spool and sleeve clearance : 0.010-0.012mm
Compensator spool and sleeve clearance : 0.008-0.010mm
Lift cylinder 6000 / 4500 / 5500 : 85.725 - 85.877mm
ROCK SHAFT
Rockshaft OD : 57.150-57.099mm
Bush ID : 57.175-57.226mm
BELL CRANK
Bell crank pin hole : 25.451-25.527mm
Bell crank pin : 25.298-25.400mm
HYDRAULIC OIL : SAE 30
CAPACITY : 14 Lt.
SPRING DATA Max. Solid Free Load Lenght

Height Length at Load
mm mm kg. mm
Flow control valve ball 18.5 36.6 7.2-8 26.2
Check valve 9.5 31.0-92.4 2.2 15.9
Check valve retainer 22.5 43.6 9.5-10.5 27.5
Spring compnsator 21.0 43.6 2.7-3.0 35.0
Spring main valve 11.9 36.3 1,2-1.3 32.0
Relief valve spring 56.9 73.2 40.3 65.2
Spring draft link 88.9 136.5 25.4 111.1
Spring draft link return
Spring position control return – 206.4 10 266.7
Draft control upper 50.3 - 49.2 56.3 - 55.1 307.5 - 359.2 49.2
Draft control lower – 139.7 1451.5-1587.6 119.1
Spring draft – 60.2 87.5 46.8 - 45.4
Piston relief valve 9.3 17.5 5.6 12.5
TIGHTENING TORQUE CHART

Oil filler plug 4.8 - 5.5 kgm
Drain plug 4.8 - 5.5 kgm
236
PCH mounting bolt 4.8 - 5.5 kgm
Control valve mounting bolt 9.5 - 11.0 kgm

Hy-Tec Hydraulics
‘O’ Ring ID ‘O’ Ring Width

Description inch (mm) inch (mm)
Size Size
A. CYL. HEAD COUNTER BORE (2 NOS.) 0.366 (9.3) 0.071 (1.8)

B. VALVE BODY COUNTER BORE
C. PISTON RELIEF VALUE PLUG
A. RELIEF VALVE SEAT 0.547 (13.9) 0.102 (2.6)

B. CYL. HEAD COUNTER BORE MOUNTING HOLE
A. ISOLATOR VALVE BUSH 0.469 (11.9) 0.102 (2.6)
A. ORIFICE ASSEMBLY 0.24 (6.1) 0.071 (1.8)
A. REGULATOR VALVE BALL SEAT 0.858 (21.8) 0.138 (3.5)

B. REGULATOR VALVE PLUG
A. CYLINDER HEAD PRESSURE INLET 0.425 (10.8) 0.102 (2.6)
A. CYLINDER HEAD PRESSURE OUTLET (2 NOS.) 0.673 (17.1) 0.102 (2.6)
A. ISOLATOR VALVE KNOB SHAFT 0.22 (5.6) 0.063 (1.6)
A. CYLINDER HEAD SPIGOT 3.0 (76.2) 0.185 (4.7)
A. CYLINDER HEAD 4.193 (106.5) 0.098 (2.5)
A. REGULATOR PISTON ASSEMBLY 0.768 (19.5) 0.138 (3.5)

B. MAIN PLUG VALVE
A. CHECK VALVE SEAT 000051182 D01 0.472 (12.0) 0.098 (2.5)
A. CHECK VALVE SEAT 000051154 D01

WITH BACK UP RING 0.551 (14.0) 0.071 (1.8)
A. RECTANGULAR 0.417 - 0.429 0.177 - 0.185

237
(10.6 - 10.9) (4.5 - 4.7)

Hy-Tec Hydraulics
Position control set to give

a desired height
Draft Control
Lever
Control set for Transporting
Fig. 2 - Arrangement of position control linkages

Position Control
1. Lever position control

2. Lever draft control
Lever
3. Cross tube
4. Connecting link
Upper Limit
5. Roller link
Position
Control
6. Bottom plate
Stop
7. Position control return spring

8. Spool
9. Draft control cross shaft
Position Control Set to give a
desired height
Position Control Set to give a
Fig. 3 - Arrangement of draft control linkages

desired height
1. Lever draft control

2. Quadrant
3. Draft control actuating link
4. Draft link
5. Spring draft link return
6. Safety chain
7. Spool
238
Fig. 1 Control settings for different modes of
operations of PCH unit

Hy-Tec Hydraulics
Fig. 4 Schematic Layout Showing Details of Control Valve

Components in Neutral Position
239

Hy-Tec Hydraulics
Legend for Fig. 4
1. Pump Inlet 21. Tank Port

2. Spacer Compensator 22. Main Plug
3. Sleeve Compensator 23. Tank Port Bypass
4. Spool Compensator 24. Orifice (0.8 mm dia)
5. Spring Compensator 25. Seat Check Valve
6. Retainer Plug 26. Ball Check Valve
7. Orifice 27. Spring Check Valve
8. Spring Regulator Valve 28. Sleeve Check Valve II. Valve
9. Ball Regulator Valve Plug
10. Regulator Piston 29. Rider Check Valve
11. Valve Plug 30. Retainer Check Valve
12. Relief Valve 31. Spring Check Valve Retainer
13. Ball Rider Relief Valve 32. Auxiliary Port
14. Spring Relief Valve 33. Isolator Valve
15. Housing Relief Valve 34. Lift Cylinder
16. Spool Control Valve 35. Tank Port Regulator Valve
17. Sleeve Control Valve 36. Tank Port Lowering
18. Pilot Port Sleeve CV 37. Piolet Line
19. Lifting Port Sleeve CV 38. Spring Main Valve
20. Lowering Port Sleeve CV 39. Relief Valve Reservoir Port
240

Hy-Tec Hydraulics
Fig. 5 Neutral Position
241

Hy-Tec Hydraulics
Fig. 6 Lifting Position
242

Hy-Tec Hydraulics
Fig. 7 Slow Lifting Position
243

Hy-Tec Hydraulics
Fig. 8 Lowering Position
244

Hy-Tec Hydraulics
3a. GENERAL flift cylinder.

1. Discription When the spool is moved to lower, the flow
These tractors are equipped with ‘Vary Touch’ through the restrictor port / pilot port (18-4) is
hydraulic system consist of an engine driven gear stoped to un seat the regulator ball and allow
type pump, and large capacity reservoir, mounted pressure from the cylinder discharge through the
on the main frame and the connecting pipes. lowering port (36-4). The non return valve / check
valve. Closes due to its spring to prevent return
The reservoir houses the operating cylinder and
oil entering the pressure line.
the suction strainer, and in addition paper filter
in corporated on suction line, with as ensured a. Position Control (Refer to figure 3, 4, 6 & 7)
100% filteration, Lift cylinder, control valves, When the positon control lever is moved to LIFT,
control valve linkage and rock shaft, carries the the linkage moves cam roller (2-9) down from the
lift arm for the three point linkages. The control lobe of the rockshaft cam (1-9). This allows the
valves provided a jack tapping to accommodate spool control plunger (10-9) to push inside control
a self sealing coupling which provides hydraulic valve under the action of return spring (12-9)
power to any equipment fitted with single acting opening the pilot port (18-4). The resulting pressure
hydraulic cylinder. A bell crank lever housed in drop allows the regulator ball to seat and pressure
the rear frame carries a top link which act as a is directed to the cylinder.
sensing arm with control valve linkage. As the rocks shaft rotate and the lift arms and
2. Principle of Operation. implement lift, the cam contacts the cam roller
The direction of flow is from the pump through to move the linkage and plunger to closed the
the reponse compenseter valve, spool control pilot port. The regulating pressure built up, moves
valve to cylinder and non return valve / checke the regulator piston to unseat the regulator ball
valve is the regulator and the restricting orifice allow pump pressure to discharge to reservoir
which also connect to the sleve control valve through the regulator port (35-4). The lift arms and
assembly. The draft and lowering the system is implement are then held by the oil locked in the
prodected by a relief valve between the pump and cylinder (34-4).
response control (compensator) valve. When the position control lever is moved to
The control valve is operated by to levers. The LOWER the cam roller (2-9) is in contact with the
inner lever (1-2) control the implement position and cam (1-9). This moves roller toward the spool
outer lever (2-2) controls Implement draft. When control valve and the acluating linkage (11-9) will
one of the levers is in use, the other lever MUST allow the spool (10-9) to come out under the action
be in the fully forward position to close the lift of spring main valve (38-4). This allow the oil to
port and open the lowering port of the circuit. Thus return from lift cylinder and discharge to the
the only flow delived to the cylinder is that reservoir causing the lift arms and implement to
controlled by the lever in use. lower under their own weight.
When the spool in use is in neutral or hold position As the rocker shaft rotates, the rock shaft cam
there will be no return to reservoir from the spool tends to move away from the roller and, in
and the pressure either side of the restricting following the cam profile the roller and linkage
orifice will equalise. As the two sides of the allow the plunger to move out until the spool
regulator piston (11-4) have different areas this control cover the sleeve port (20-4) then the lift
pressure will have more effect on the greator face arms and implement are again held by the oil
thus moving the piston to hold the regulator ball locked in the lift cylinder.
(9-4) off its seat allowing pressure oil to pass the As the pump pressure is unchanged the regulator
ball and return the reservoir through the regulator ball will be held off its seat and pressure oil
port (35-4). discharges to reservoir.
When the spool is moved to open the lift port (18- NOTE : The distance raised depends onthe movement
4) to reservoir, the resulting flow through restricting of the position control lever in quadrant.
orific will cause the pressure drop at the regulator b. Draft Control (Refer to fig. 3, 4, 8 & 10)
allowing the regulator ball to seat. The pressure 245
The draft control system operate on the principle
will then open the non return valve/check valve
of draft loads i.e. resistance acting on the
against its spring and allow pressure to reach the

Hy-Tec Hydraulics
1. Cam Position
Control
2. Roller
3. Roller Link
4. Cross Tube
5. Quadrant
6. Position Control
Lever
7. Position Control
Crank
8. Connecting Link
9. Position Control
Support Bracket
10. Spool Control
Valve
11. Position Control
Actuating Link
12. Position Control
Return Spring
13. Lug
Fig. 9
Internal Linkages Layout - Position Control
1. Top Link Crank

2. Bolt Draft Plunger
3. Draft Plunger
4. Draft Link Clevis
5. Rocker Arm
6. Spring Draft Link
7. Draft Link
8. Quadrant
9. Draft Control Lever
10. Draft Control Crank
11. Spool Control Valve
12. Draft Control
Actuating Link
13. Safety Chain
14. Draft Link Return
Spring
15. Top Link Spring
16. Top Link Spindle
246
Fig. 10
Internal Linkages Layout-Draft Control

Hy-Tec Hydraulics
implement while it is being pulled through the signal at the top link. If these signals are small
ground. Load, actuates the draft plunger which is the spool control valve (16-4) will send small
linked to the draft control spool of the valve. amount of oil to cylinder and rest of pump flow
The position of the draft control lever (9-10) will be by passed to tank by compensator valve.
corresponds with a definite resistance of the (3 to 5-4) through by pass tank port (23-4). This
implement being pulled through the ground. will result in small movement of lift cylinder and
implement. If there is comparatively more draft
The implement penetrates into the ground until the
signal, control valve will send comparativly more
pre selected operating resistance is reached. At
oil to lift cylinder and there will be more
this point the draft control linkage top link, bell
movement of implement. Thus the draft control
crank / top link crank (sensing element) acts on
system is proportional to the signal.
the sensing bolt draft plunger (2-10) which is
connected by the draft link clvis (4-10) and d. Draft control / sensing element.
operating link (7-10) and draft control actuating 1. The Tension or pressure forces acting on the Top
link (12-10) to the spool control valve (11-10) or link spindle sensing element (see fig.13) are
(16-4). converted into control signal i.e.
An increase in implement draft moves the draft These signal are taken up by the bell crank and
link plunger (3-10) against the spring thus move transmitted to the spool control valve (11-10) for
the spool control valve plunger. lifting or lowering action.
As the spool plunger moves inward. The pilot port 2. Operation
sleeve is uncovered, the consequent pressure drop In draft control mode, the lever is set at particular
allow the regulator ball (9-4) to sear and pressure position on the quadrant, top link attached to top
is directed to the cylinder to raise the lift arms link crank. (1-10) under the top link force the top
and implement. As the implement is raised, the link spring (15-10) will deflect. This displacement
compression load onthe top link is reduced and is passed to draft plunger (3-10) which is kept
the top link crank (1-10) will go back and allow away from the contact with top link crank (1-10)
the spool control valve to move out by action of by return spring (14-10). The movement of draft
the draft link return spring (14-10). The spool cuts control plunger is transfered to spool control valve
off the pilot port and resulting pressure rise (11-10) with certain amplification through draft link
unseats the regulator ball to allow pump pressure (7-10) and draft control actuating link (12-10). This
to return to reservoir. A decrease in implement draft results in lifting of implement in operation till the
allow the draft link plunger (3-10) to move out set force is reached. If the implement is lifted
taking the spool control valve (11-10) with it. This more then required which will reduce the top link
uncover the lowering port (20-4) see fig.7, allowing crank back ward will lower the hitch till the set
the lift arms and implement to fall until the draft is achieved.
increase in implement draft moves the control
e. Check Valve (see Fig. 4)
spool through the linkages to close the lowering
port. The ball (26-4) is kept on its seat by the spring
(27-4) until pressure in the pump line is
The draft control lever, by moving the draft control
approximately 75 PSI. This ensure that in the
crank (10-10) of the operating link / draft control
drop position the lift arm fall will not be allowed
actuating link (12-10) move the draft link relative
by low pressure oil, which is circulated by the
to the bolt draft plunger this movement is
pump to the reservoir through the regulator port
transmitted to the control spool and oil flows in
(35-4) the check valve also locks the oil in the
the appropriate direction until the resulting
cylinder when controls are in the natural (or hold)
movement of the lift arms brings the implement
position.
draft to the desired setting. The spool then returns
to the neutral position to cut off the oil flow. f. The Relief Valve (see Fig. 25)
c. Proportional draft control (see fig. 8) The relief valve ball (12-4) become unseated
allowing the high pressure oil to drain to the
The proportional draft control system is new
reservoir through port (39-4) when the pressure
design on these models is introduce, instead of
in the system exceeds the specified figure and
slow-fast control with a separate Knob. The 247
overcomes the spring (14-4). The relief valve is
proportional draft control means, the implement
not adjustable. For adjustment refer to para 9b.
will move depending up on the amount of draft

Hy-Tec Hydraulics
g. Cylinder cushion valve Repair or replace the pump if capacity is less

This valve is fitted on the cylinder pistion. The than 75% of normal value.
purpose of the cylinder cushion valve is to protect c. Relief valve pressure
the system against shock loads when driving over Install a pressure gauge (-0-210 kg/cm2) 3000 PSI
a bumpy road with a bouncing implement. In this in the external jack tapping. (32-4) (auxiliary port)
pressure way due to shock loads or many with the draft control lever in the top most position
thousand and p.s.i. may result. As soon as these and the engine at full throttle the pressure should
shocks exceed specified limits the cylinder be as per specification.
cushion valve (see fig. 23) will become unseated,
WARNING :
relieving pressure in the power cylinder.
1. To avoid over heating of the system the pressure
CAUTION : Never drive with the position control test should not be maintained for more than 30
lever against the upper limit stop seconds.
h. Remote Cylinder 2. After completion of the test the draft control lever
To operate, single-acting cylinders, the adjustable must be return to the deepect position other wise
stop is moved to contact the upper limit stop, the serious damage to the hydraulic system may
position lever is then used to raise the lift arms result. If the recorded pressure is not as per the
full. Close the isolating valve (33-4). With the specification while the relief valve is operating,
position lever against the adjustable stop, the the relief valve spring must be checked as the
remote cylinder is in the neutral or hold position. valve is adjustable.
To operate the remote cylinder the lever is spring If the relief valve is OK and not getting specified
over the adjustable stop until it is in contact with pressure, either the compensator spool has stuck
the limit stop. The valve operation for remote in the fully opened position or the pump efficiency
cylinder LIFT and as soon as, cylinders are is low.
extnded, return the position lever to the hold d. Back Pressure
position. To allow the cylinder to retract, move the
With the draft control lever in the deepest position
lever forward from the hold position
and the position control lever in the full lower
4. TEST PROCEDURE position, the gauge should read zero.
a. General e. Speed of Lift and Lower
Before Investigation any service problem the Move the position control to lift. Full lift should
following basic points should be checked Hydraulic be completed in not more than three seconds.
system that has failed step by step. Move the lever to lower and check that it is
– Fluid level possible to control the drop so that at least two
– Age condition, and type of fluid seconds are taken for a full drop.
– External leakage f. Isolating Valve Leakage
– Air in the system Raise the weights fully then close the isolating
– Operating temperature of 50º–20ºC. valve.
The Test procedure covers the following tests. With the control lever in “Lower” there should be
no more than 0.127mm drop of the lower link ends
1. Hydraulic pump capacity
in 30 seconds.
2. Plain relief valve setting
WARNING : Open the isolating valve fully afte
3. Cylinder cushion valve setting
the above test.
b. Hydraulic pump capacity may be measured
g. Position Control Valve Leakage Test
when pump is installed, or on a test bench.
Fully lift the weights (600kg) then return the
Test valves see specification.
position control lever to a mid position. There
Pump is designed for 40 Lts. must be no more than 0.3mm drop of the link
Maximum permissible operation speed 2300 rpm. ends in 30 seconds.
248 Maximum permissible pressure (Hydraulic lift With the lever in the lowest position the link ends
element) 21 kg/cm2 must be not more than 127mm from the ground.

Hy-Tec Hydraulics
1 b. Remove external jack tapping plug. Fit special

9 2
tool MST-H1/2-HD-12 (fig.-11a) & MST-H1/2-
HD-11 (fig.-11b)
7 3
8 4
6
Fig. 11a
Fig. 11
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 Fig. 11b
6. Bypass Tank Port
7. Plug Connecting Pump, Relief Valve & Control c. Connect the hand pump (injecter tester) to the
Valve external jack tapping (fig-11c)
8. Port Conecting Regulator Bore to reservor
9. Regulator Valve Bore
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.
Fig. 11c
Measure the height of the ball ends from the d. Screw in the isolator valve.
ground. If these two measurements differ by more
e. Hole the spool at the full lift position (inside).
than 25.4mm. The control valve spool may sticky.
f. Raise the pressure to 125-140 kg/cm2. Do not
i. Noise
raise the pressure sufficiently to blow the relief
There should be no noise from any part of the valve. Wait for 2-3 minutes and observe plugs (3,
hydraulic system apart from a slight hiss caused 4&7-11) and ports (5, 6&8-11) for leakage. If any
by oil flow. of these plugs are leaky tighten it or replace if
j. Pressure Testing the Valve Unit Before required.
Assembling to the Housing g. IF oil is coming out from coupling pressure pipe
a. Clean the control valve with help of air & make (14-10), or port (9-3) ‘check valve’ is leaky, 249
it dry. remove check valve and observe sear for any

Hy-Tec Hydraulics
damage, observe ‘O’ ring for any cut and connecting hose (13-16A) off the filter pipe.
deformation etc. Before reassembling, change ‘O’ 6. Disconnect the high pressure pipe from the Valve
ring on seat. Body Showing Different Ports & Bores control
h. After reassembling, observe the pressure guage, valve pull the strainer (10-16A) from the housing.
if the pressure is coming down, and if oil is Without damaging ‘O’ ring on it.
leaking from (4-11) clearance between main spool 7. Disconnect the pressure pipe, pump to auxiliary
and sleeve is more than (0.010-0.012)mm. valve inlet.
Replace the spool with the spool of bigger 8. Disconnect the pipe from auxiliary valve to main
diameter and do necessary lapping. control valve.
5. REMOVAL 9. Remove the auxiliary valve by removing three
a. General bolts of mounting plate.
Before starting to removal hydraulic components, 10. Remove the hydraulic housing bolts and siling the
be sure to wash the tractor throughly. On a dirty hydraulic housing securely with a suitable hoist.
tractor the hydraulic system must not be opened. 11. Free the housing from dowel pins and lift it.
Be sure so cap all ports and ends of hydraulic. – Remove all mounting bolts (20).
Even the smallest particals of foreign matter may – Using a suitable hoist lift the housing clear
cause trouble. Plan your work before starting to of the main frame.
remove units.
NOTE : To facilitate handling of housing it is advisable
b. Hydraulic Lift Housing to make a stand with a swivelling base plate.
1. Drain the reservoir by removing the plug (1-12). This plate should have four mounting holes
2. Remove the lift Rods (5-12) & top link by retainer bolts and cut out large enough to
removing the attaching cotter pin (2-12) and pin make the housing accessible from the
(3-12). bottom.
3. Withdraw the quick release pin (6-12) and top link The Draft Control (Bell crank assembly)
pin (7-12) then lift the telescopic link (8-12). c.
4. Remove the Seat and clear of the tractor. 1. Remove the lock plate (1-13A) and drive out the
5. Remove the connecting hose guard by removing pin/shaft (5-13) releasing the bell crank (2-13).
two bolts from shifler cover then. Disconnect the 2. Remove the lock nut (6-13) and screw the rod,
suction line by loosening the two clamps of pipe complete with all components, from trunnion
suction assembly to filter (12-16A) slide the (2-15).
3. Remove the spring (4-15), seat spring (5-15) and
7
6 trunnion from the housing (2-15).
9 5
2 4. Remove the cotter (13-15) and nut (12-15) from
3 1
the rod (11-15) the slide off the two spring seats
(8&10-15) and spring.
5 6 4
4
8 3
1 2
Fig. 13
250 1. Draft control plunger 4. Oil filler plug
2. Bellcrank 5. Shaft/pin top link crank
Fig. 12
3. Spring top link 6. Lock nut

Hy-Tec Hydraulics
7 5 5. Pull the scraper seal (6-15) from the Housing.

6
d. The Cover Plate
Remove the top cover plate (6-13A) by removing
eight bolts.
(i) The Quadrant
1. Remove the connecting link (1-17) by
removing the cotter pin and washer.
1
2. Remove the four quadrant retaining bolts (14-
4 14) the draw out the quadrant assembly and
3 crass shaft. (See fig.18)
2
Fig. 13A
1. Lock plate 5. Cap screw
2. Spring top link (Draft) 6. Top cover plate
3. Drain plug 7. Lift arm
4. Lift arm retaining plate
3 13
2
15
16
1
14
4 16 15 5 15 6 7 15
11 10
12
9 14 Fig. 15
Fig. 14 - Precision Control Hydraulic Unit 1. Nut Hex. 3/4 (Lock Nut) 10. Seat Spring
2. Trunion 11. Spindle Top Link
1. Draft Control Lever 10 Cylinder Head 3. Spacer Top Link 12. Nut Slotted 3/4 UNC
2. Position Control Lever Control Valve Spindle 13. Pin Cotter 3/16 x 1¼
3. Isolotor Valve Knob 11. Lift arm Retaining 4. Spring Top Link 14. Crank Top Link
4. Housing for Suction Filter plate 5. Seat Spring Small 15. Grease Nipple 1/8
5. Pressure Pipe Connection 12. Bolt Retaining 6. Ring Scraper WY Clip NPT
to PCH Plate 7. Oil Seal Top Link 16. Top Link Crank Shaft
6. Plug for External Tapping 13. Top Cover Plate Spindle 17. Plate Lock Top Link
7. Orifice filter plug 14. Bolt 8. Seat Compression 18. Tab Washer
8. Lift Arm 15. Bolts Control Valve 251
Spring 19. Bolt Hex. 5/16 UNC
9. Quadrant Mounting 9. Spring Top Link x 5/8 Long
16. Bolt Cylinder Head

Hy-Tec Hydraulics
e. Dismantling the Quadrant 2 1

1. Remove two cap screws and remove the quadrant
strip (2-18).
2. Remove the nut then remove the components
from the shaft in order shown in fig 18.
3. Remove the quadrant plate (16-18) by removing 7
four nuts and bolts. 3
4. Remove the circlip (22-18) and draw out the draft 4 9
control shaft (30-18) with the spring and washer 5
8
(29,&28-18). 6
10
NOTE: There are two ‘O’ rings (23-18) in the Braket
control lever (24-18).
Fig. 16
!
WARNING : The circlip hold the spring in ‘Vary-Touch’ Hydraulic Controls
compression and care must taken to avoid injury while
1. Position Control Lever 7. Draft Control Lever
releasing spring.
2. Upper Limit Stop 8. Auxiliary Tapping
f. The Crosstube 3. Quadrant (Self sealing
4. Draft Control Sector coupling fitted)
1. Remove the two pivot and dowty washers with
5. Position Control Stop Screw 9. Isolating Valve
special tool MST-H1/2-HD-5 (fig.-15a & 15b)
6. Draft Control Sector Screw 10. Suction Strainer
2. Lift the cross tube and disengage it from roller
link (5-2) and take out cross tube (3-2) with
5 9 4
connecting link (1-17).
7
8
3
Fig. 15a
1 2
Fig. 17
Position Control
Fig. 15b 1. Connecting Link 6. Draft Push rod

2. Cotter Pin and Washer 7. Safety Chain
3. Draft Control Shaft 8. Cylinder
252 4. Relief Valve 9. Position Control
5. Roller Link return spring

Hy-Tec Hydraulics
1
7 14
16
8
13
15 10
11
12
6
5
2 3
4
5. Compensator sleeve 11. Plug assy retainer

6. Compensator spool 12. Spring
1. Cylinder Head 7. Isolating Valve 13. Regulator filter
2. Adaptor 8. Seat Isolating 14. Plug
3. Dowty washer 9. Regulator filter 15. ‘O’ Ring
4. Compensator spacer 10. Circlip 16. Dowty washer
Fig. 19
The Cylinder Head
253

254
1st Version 4th set.pmd

30 29 24
254
Hy-Tec Hydraulics
27
1. Wing Nut
2. Central Lever Quadrant Strip
3. Bolt 3/8 UNC 3/4
4. Slide Assembly Draft
5. Knob Draft Control Lever
6. Lever Draft Control with Hub
7. Disc Friction Outer Position
8. Plate Friction
9. Disc Friction Draft Lever
10. Lever Position Control with Hub
11. Knob Position Control Lever
12. Circlip 24 mm
13. PC Adjustable Stop 23. 'O' Ring 1 X 1/4 X 1/8 (Plate)
14. Bolt Lock Position Control (on Position Control Sleeve)
6/3/2006, 11:17 AM
15. Washer 3/8 Spring Lock-Plated 24. Bracket Control Lever
16. Quadrant Plate 25. 'O' Ring 9/16 X 3/32 (PS 152)
17. Washer Pair13/32 X 13/16 X 16 h (on Draft Control Shaft)
18. Position Control Stop 26. Gasket Control Lever Brackets
19. Bolt 3/8 UNC X 1-1/4 Hex. Head 27. Sleeve Complete Position Control
20. Washer 3/8 Spring Lock-Plated 28. Washer Tab
21. Nut 3/8 UNC PLTD 29. Draft Control Crankshaft Spring
22. Circlip External 19 mm 30. Draft Control Crankshaft CPTE
Fig. 18 - Quadrant Assembly

Hy-Tec Hydraulics
13
14
16 15
17 12
8
9
11
10
Fig. 20
1. Spring check valve Relainer 10. ‘O’ Cylinder Head Spigot

2. Check valve retainer 11. Cylinder Head Spigot
3. Check valve sleeve 12. Orifice filter conter bore
4. Spring check valve 13. Cyl. Head Conter bore
5. Ball Rider 14. Cyl. Head Pressure inlet
6. Ball 15. Cyl. Head Pressure outlet
7. Seat check valve with ‘O’ Ring 16. Orifice Plug
8. Cylinder Head 17. Compensator Valve tank port
9. ‘O’ Ring groove Cylinder
g. Removing auxiliary valve 2. Remove the two small attaching capscrews

1. Remove the pressure pipe connection (2-16) at (16-14) and draw off the cylinder head releasing
auxiliary valve. Came from the Tendem pump to the spring (1-20).
Auxiliary valve. j. Dismantling Check Valve
2. Disconnect the pressure pipe valve to control 1. Takeout the spring (1-20) which released by
valve Inlet (1-16). cylinder head split off from control valve body.
3. Remove Auxiliary mounting bolts (16A) and take 2. Takeout check valve retainer (2-19), then sleeve
out. (3-20), Spring (4-20), Rider (5-20) & ball (6-20).
4. Remove Auxiliary mounting plate from the 3. Pullout the seat check valve (7-20) with the help
hydraulic housing by removing three bolts. of special puller.
h. Removing Components from the Cylinder Head NOTE: a) Care should be taken while removing
1. Remove the regulator filter (9-19) with the dowty sear check valve such that sear is
washer and “O” ring. protected from scratches/marks.
2. Remove the high pressure pipe adaptor (2-19) and b) Thread are provided for pulling out the
draw out the compensetor spacer (4-19). seat.
3. Remove the circlip (10-19), plug with “O” ring, (11- 4. Remove the cylinder head ‘O’ ring from groove
19) spring (12-19), spool (6-19) compensetor (9-20) and from spigot (10-20).
sleeve (5-19). 5. Remove the cylinder head five port ‘O’ rings
(12,14,15,16,17-20).
! WARNING : Care must be taken to avoid Injury
while removing the circlip as the plug holds the spring k. Removing control valve from the cylinder
in compression. 1. Disengage the position control return spring
4. Remove the isolator valve (7-19) by removing the (9-17) from position control actuating link refer (7-
two attaching cap screws. 2).
5. Dismental the isolating valve by driving out the 2. Remove cross tube by removing pivots.
pin if necessary. 3. Remove split pin and washer (6-20A) and remove
i. Removing the Cylinder Head (Refer fig.14) pin connecting (5-20A) to disconnect safety chain 255
1. Remove the eight attaching capscrews (15-14).

Hy-Tec Hydraulics
8 6
1 3 4 5
4
1
5
6
3
2
7
7 2
Fig. 22
1. Bolt draft control 6. Draft control

Fig. 20A 2. Draft control plunger actuacting link
3. Draft link clevis 7. Safety chain
1. Rockshaft 5. Pin connecting rod
2. Roker arm 6. Split pin/cotter pin 4. Spring Draft link 8. Draft link return spring
3. Rod connecting 7. Oil seal top link 5. Draft link
4. Safety chain spindle
(Teflon) (4-23).
(4-20A). 3. Remove the plug (8-23) ball (7-23) ‘O’ ring, ball
4. Remove eight control valve mounting bolts (15- rider (10-23) & spring (9-23).
14). m. Dismantling the Control Valve
5. Draw out the complete assembly together withthe
position control linkages. (1-21) and Drought 1
5
control push rod (6-22) see fig. 22
6 8
3
6. Remove the position control linkage from the body 4 7
by removing the Allen screw see fig. 21 10
9
l. Dismantling the Piston
1. Slide the piston (3-23) from the cylinder sleeve
(2-23).
2. Remove the two sliding rings and one guiding ring 2
5
6 Fig. 23
1. Control valve body 7. Ball
2. Cylinder sleeve 8. Plug
3 3. Piston 9. Spring
4. ‘O’ ring seal (Taflon) 10. Rider
7
5. Relief valve
2 5 6. Spool
1
1. Remove the circlip (3-24) by using a pointed
1
pocker tool and take out the spool (2-24) by hand.
2. Pull out the plug (4-24) with “O” ring and spring
9
8
control valve (5-24) from the front side.
a) Do not drive out the sleeve.
4 b) Fitting of the sleeve is shirk fitted.
3. Seperate spool end cap (6-24) by removing allen
Fig. 21
screw (5-24).
1. Position control linkage 5. Dowell
n. Dismantling the Regulator Valve
asembly 6. Cylinder
256 2. Bracket P.C.linkage assy. 7. Control valve 1. Remove the circlip (14-24) then the plug (13-24)
3. Spool 8. Relief valve Assy. with “O” ring.
4. Allen screw 9. Regulator valve

Hy-Tec Hydraulics
1. Sleeve control valve

2. Spool control valve
3. Circlip
8 9 10 11 12 13 14 4. Plug main sleeve
5. Spring main valve
6. Main valve end cap
7. Allen screw
8. Spring flow control
valve ball
9. Rider
10. Ball
11. Valve ball seat
12. Regulator piston sub
4 1 5 2 3 6 7
assy.
13. Plug valve
14. Circlip
Fig. 24
Control valve and Regulating valve components
1. ‘O’ Ring Pump Port 13. Regulator Piston

2. Spacer Relief Valve 14. ‘O’ Ring
3. Seat Relief Valve 15. Braring Ring
4. ‘O’ Ring 16. Valve Ball Seat
5. Ball Relief Valve 17. ‘O’ Ring
6. Ball Rider 18. Plug
7. Spring Housing 19. Ball Flow Control
8. Spring Relief Valve Valve
9. Shims 20. Rider Ball
10. Plug Valve 21. Spring
11. Circlip 22. ‘O’ Ring
12. ‘O’ Ring
6
5
4
2
257
Fig. 25
Cross Section of Regulator Valve and Relief Valve Assembly

Hy-Tec Hydraulics
Fig. 26a
2 3
Fig. 26
1. Rocker Arm 2. Rocker Arm Bolt
3. Rockshaft
2. Pull out the piston (12-24) with ‘O’ ring.

3. Using special tool MST-H1-HD-4 (fig.-26a & 26b),
screw out the valve ball sear (11-24) with ‘O’ ring,
then ball (10-24), ball rider (9-24) & spring (8-24).
Fig. 26b
1. Bolt Long
2. Washer
3. Plate Lift Arm Retaining
4. Lift Arm
5. Oil Seal Rockshaft
6. Washer Rockshaft
7. ‘O’ Ring Rockshaft
8. Bush (Sleeve) Rockshaft
9. Rockshaft Hydraulic
10. Arm Rocker Hydraulic
11. Rocker Arm Bolt
12. Cam Rockshaft
13. Rod Connecting
14. Pin
15. Pin Cotter
16. Bush Connecting Rod
17. Safety Chain with Sleeve
258
Fig. 27

Hy-Tec Hydraulics
o. Dismantling the Relief Valve re-use of worn parts will inevitably result in early
1. Screw out the spring housing (7-25) then remove failure and is false economy.
the spring (8-25), rider (6-25) BALL (5-25) RELIEF 7. ASSEMBLY
VALVE SEAT (3-25) with “O” ring, (4-25) & spacer a. General
(2-25).
1. Extreme cleanliness must be observed during the
p. Removing of the Rockshaft assembly of hydraulic units. Dirt will cause rapid
1. Remove the retainer capscrew (5-13) and washer wear of parts resulting in faulty operation and
(4-13) then draw off the lift arm (7-13) right and eventual failure of the unit.
left hand. 2. Lightly coat all parts with the correct grade oil
2. Remove the connecting rod (3-20A) by removing before assembling.
the pin (5-20A) and cotter pin (6-20A). 3. Use new “O” rings, gaskets, oil seals and copper
3. Remove the lock bolt (2-26) then drive the rock washers during assembly.
shaft (3-26) from the left hand side out through b. ASSEMBLING THE ROCKSHAFT AND ROCKER
the right hand side. ARM.
NOTE : Right hand side bush (8-27), washer (6-27) 1. Slide the shaft (9-27) through the housing from
and oil seal (5-27) will come out with the shaft the right hand side at the same time assembling
and the rocker arm (10-26) and cam (12-27) the rocker arm (10-27) and cam (12-27) to the
will be left loose in the housing. splines.
4. Drive out the left hand bush (8-27) & oil seal NOTE : (a) There is an interrupted spline on the shaft
(5-27). to align the rocker arm, cam and lift arms.
6. CLEANING, INSPECTION AND REPAIR (b) To ensure that the cam is assembled
a. Cleaning correctly, the chamfered end of the cam
1. Clean all components in a solvent and blow dry bore MUST be located against the rocker
arm (4-27).
with compressed air.
2. Locate the rocker arm on the shaft then insert and
2. Rags must NOT be used to wipe parts dry as lint
tighten the lock bolt (2-26).
may be left which will lodge under valve seats
or clog filters. This is particularly liable on rough 3. Press in the bushe, (8-27) then install the washers
castings and in threads. (6-27).
3. Blow out all oil passages with compressed air and 4. Press in the oil seals with the lips facing the
ensure that all foreign matter is removed. inside of the housing.
4. Plug or tape all openings as soon as possible and NOTE : A sleeve must be used to prevent the
keep all parts in clean containers. splines damaging the seal lips.
b. Inspection 5. Assemble the connecting link to the rocker arm
1. Inspect all parts for wear, scores or burrs. by installing the pin and cotter.
2. Burrs may be removed with a fine carborundum 6. Assemble the lift arms to the rockshaft splines
stone but care must be taken not to remove the and install the retainers (3-27) and capscrews
sharp edges on valves or spools. (1-27) with lock washer ‘O’ ring (7-27), in between
two bushes.
3. Inspect all castings for cracks and damaged
threads. 7. Assemble bottom cover plate (6-2) and attaching
two springs (7-2) and (5-3).
4. Check all springs according to
“SPECIFICATIONS”. c. ASSEMBLY OF THE VALVE BODY
5. All “O” rings, copper washers and seals should Assembly of Relief Valve
be discarded and new parts used on assembly. 1. Insert spacer relief vale (2-25), then sear relief
c. Repair valve (3-25) with ‘O’ ring (4-25).
1. Apart from removing burrs, no repair should be 2. Insert ball (5-25) and ball rider (6-25).
undertaken. Any damaged parts should be 3. Insert spring (8-25), then spring housing (7-25) 259
replaced with new. with shims if required to adjust specified pressure
2. If a part is worn it should be replaced. The by adding or reducing shims.

Hy-Tec Hydraulics
4. Screw the relief valve housing (7-25) down, h. Assembly of Check Valve
securely using a tommy bar through the upper 1. Install seat check valve (7-20) with ‘O’ ring from
hole. front side.
d. Assembly of Regulator Valve 2. Install ball (6-20), rider (5-20), spring check valve
1. Place the spring (8-24), ball rider (9-24) & ball (10- (4-19), and ball sleeve (3-19) in the sequence
24) in the housing then screw in the valve ball shown in the fig. 20.
seat (11-24). 3. Insert check valve retainer (2-20) & spring (1-20).
2. Slide in the piston with ‘O’ ring (12-24), then the NOTE : Ensure during the assembly that spring
plug with ‘O’ ring (13-24) & secure with the circlip retainer is properly seated in the bore on the
(14-24). cylinder head face.
e. Assembly of Control Valve i. Assembling the Cylinder Head on Valve Body
1. Insert the spring valve (5-24) from cylinder head 1. Install the cylinder “O” ring port ‘O’ ring. see fig.
side port. 20. (9,10,12,13,14,15,16,17-20) 8 ‘O’ ring.
2. Install the plug control valve (4-24) with ‘O’ ring 2. Slide the cylinder head spigot into the cylinder.
from the cylinder head side. and press cylinder head and control valve body
3. Install the spool (2-24) in to the sleeve control by hand secure two coupling bolts (16-14).
valve (1-24) and Install the circlip (3-24).
4. Fix the spool end cap (6-24) by on spool (2-24)
by allen screw (7-24).
NOTE : After assembly, by hand ensure that the
spool movement is not sticky and it is
moving smoothly
f. Assembly of Piston
1. Install the relief valve spring (9-23), ball rider
(7-23) and plug (8-23) tighten plug securely.
2. Assemble the piston seals (4-23), with lips toward
cylinder head side install ‘O’ Rings Rectangular
section seal ring and ring outer seal. Dip the
Fig. 28 - Return Line Filter
piston in oil.
j. Assembling the Position Control linkage on
3. Press fit the cylinder sleeve (2-23) in the valve
Valve Body (Refer fig. 21)
body (1-23) using the proper dolly.
1. Insert the locating dowell (5-21) in the hole.
4. Slide the piston (3-23) into the cylinder taking
care not to damage the seal. 2. Fit the position control linkage bracket (2-21) in
the dowel with roller linkage.
g. Assembling Componants in the Cylinder
3. Fit the bracket by securing the Allen bolt.
1. Assemble seat isolating (8-19) if it was removed
for replacement. k. Assembling the Controls Valve to lift Housing
2. Assemble the isolating valve assembly (7-19) and 1. Install the gasket on valve body.
screw into the bore. 2. Slide the control valve assembly with position
3. Screw the two attaching capscrews. control linkage into the reservoir.
4. Place the spacer (4-19) with a dowty washer 3. Insert the eight retaining bolts.
(3-19). 4. Assemble the connecting link to the pivot.
5. Slide the compansator spool (6-19) into the bore, l. Assembling the Controls Quadrant
followed by the spring (12-19) and plug assembly 1. Slide the spring and washer onto the draft control
retainer (11-19) with ‘O’ ring and secure with shaft (30-18) then slide on the position control
circlip (10-19). tube (27-18).
6. Install the regulator filter (13-19) with ‘O’ ring and 2. Compress the spring (29-18) and install the circlip
260 plug (14-19) with a dowty washer. (22-18).
7. Install the plug auxiliar tapping with dowty washer. 3. Slide the assembly through the housing aligning
washer tab in the slot in the housing.

Hy-Tec Hydraulics
4. Install the ‘O’ ring (23-18) the bolt onthe quadrant (g) Engage the bellcrank forks with the trunnion and
(16-18). drive in the pin (13-15) with the plate slot towards
5. Assemble the levers and washers in the order the right hand side.
shown in the fig 18. 8. INSTALLATION
NOTE : Ensure that locating washer (8-18) is located a. The Hydraulic Lift Housing
on the dowel and that the punched mark on 1. Place a new gasket on the frame the lower the
the control levers are aligned with the unit into position and secure with the capscrews.
corresponding marks on the control shaft
2. Place the rear wiring harness and conduits in
splines.
position on both sides of the lift housing.
6. Screw on and tighten the retaining nut (31-18).
3. Position the self sealing coupling and bracket at
7. Slide the assembly (fig.18) with gasket rear of the housing, then insert and tighten the
(24-18) into the housing engaging the peg on the
securing, capscrew.
draft control shaft (fig.17) with the draft link.
4. Install the auxiliary valve assembly on hydraulic
8. Insert the four securing cap screws.
housing by three mounting bolts.
9. Install the position cross shaft by engaging the
5. Connect the self sealing coupling pipes, banjo
pin in the slot of the left hand position control link
union and the high pressure pipe to the auxiliary
(5-17) (Roller link) then installing the two pivot
valve and control valve.
studs with the dowty washers.
6. Slide the connecting hose (13-16A) from the
10. Connect the right hand position control link (1-17)
suction line onto the filter pipe and tighten the
by installing the washer and cotter pin (2-17).
hose clip (12-16A).
11. Attach the draft & position control spring (9-17)
7. Replace the Hydraulic oil filter element before
which is attached to the lower cover plate (fig.
installation of Hydraulic unit. (After completing
2-6)
repairing job) check the filter connections for
m. Assembling Cover Plates spilling of oil.
1. Attach the draft push rod return spring (7-22) to 8. Install the seat and three point linkages.
the lower cover plate then screw the attaching
capscrews making sure the gasket is carefully 9. Tighten the drain plug.
installed. NOTE : The drain plug should be installed using
2. Tighten the plate carefully and equally to prevent sealing compound. Seating compound should
leakage of the hydraulic oil into the transmission not be used in any other application in the
case. hydraulic system.
3. Install the top cover plate. 9. Fill the reservoir with the correct grade of oil and
tighten the filler cum dip stick gauge plug. Refer
n. ASSEMBLING THE DRAFT CONTROL
to the “OPERATOR’S MANUAL” for details of
SPRINGS AND BELLCRANK
“LUBRICANT SPECIFICATIONS”.
(a) Press the scraper seal (6-15) in housing.
10. Install the pump to the timing case with the drive
(b) Place the spring seat (5-15) spring (4-15) and coupling meshing with the jaw coupling and
trunnion (2-15) in position then screw in the rod. secure with the four bolts, if it has been removed
(c) Screw the rod (11-15) in until the shoulder on the for any reason. (fig.29)
rod contacts the spring seat and all slackness is b. Assembling the Hydraulic Pressure Pipes
taken out of the assembly but DO NOT compress During Hyd. Pump Subassembly
the spring.
1. Attach the suction and pressure pipes to the
(d) Screw on and tighten the lock nut (6-13).
tendem of front & Rear pump as follows.
(e) Assemble the spring seat (8-15) spring (9-15) and
a) Tighten the nut of the pressure pipe
seat (10-15) then screw on the nut (12-15) until
(pumpend) till the progressive bite of the
all slackness is taken out of the assembly but
ferrule is achieved. Make sure that the pipe
DO NOT compress the spring.
is butted the end of manifold during tightening.
(f) Align the pin hole in the rod and insert the cotter
b) Assemble the connector and pressure pipe
(13-15).
(at control valve end) and tighten till the
NOTE : It is important that these springs are tightened progressive bite of the ferrule is achieved 261
to remove slackness but the springs must not (both side).
be compressed.

Hy-Tec Hydraulics
c) Loosen all the Joints of pressure pipe, So that 4. Adjust the plunger length by screwing or
it is easier for alignment during final unscrewing the plunger adjusting bolt (2-10) such
assembly. that lift start at this lever position and comes to
NOTE : Progressive bite of the ferrule can be the top most position.
achived by tightening 1½ turns after finger- 5. Lock the plunger adjusting bolt at this position by
tightening. tightening the jam nut & apply the liquid sealant
2. Final Assembly of pressure pipe. locktite 243 to jam nut.
a) After pump mounting following is the 10. SERVICE INSTRUCTIONS
tightening sequence of the joints 1st connector a. Adding Oil
(both nuts)-2nd control valve end. After every 250 hrs. of operation, check the level
9. ADJUSTMENTS of oil in the hydraulic reservoir. Clean the area
a. Adjusting the Position Control around the filler/level plug before removing the
plug. Add oil of specified grade up to the slotted
Connect the lower links to a dead weight of
mark given on dipstick whenever required.
600kg.
b. Replacement of suction filter
Open the isolating valve and set the draft lever
to the deepest position. Lift the weight by Replace the filter after every 500 hrs. as per
operating position control lever slowly until the procedure mentioned below.
distance from the center line of the top hitch pin 1) Put a clean tray below suction line filter.
to the center line of the lift arm pin is 620mm 2) Unscrew the filter cartridge and collect the oil in
lock the position control lever stop firmly behind the tray.
the lever in touching position.
3) Apply oil on ‘O’ ring of the new filter.
NOTE : Check that this is correctly set by lowering
4) Assembled it with hand as per give instruction on
and lifting to the top again with the position
the filter.
control lever. It should now be possible to lift
the links a further 12.5mm approximately by 5) Add oil if necessary.
moving the draft control lever to the top most 6) Remove air as per instruction given below.
position. c. Changing the oil
b. Checking the relief valve pressure. Fit pressure After every 1000 hrs. of operation system should
gauge (0-214 kg/cm2) in the external jack tapping. be drained, strainer cleaned, oil refilled as follows.
Close isolating valve. Put engine to full throttle 1) Clean the area around the filter plug, suction
and lift the draft control lever in the top most strainer & orific filter.
position the pressure reading should be as per
2) Remove drain plug then allow the oil to drain in
specification (158-193 kg/cm2 and 140-175 kg/cm2)
to a suitable container, remove the orifice filter,
! WARNING : To avoid overheating the system the clean or change.
pressure test should not be maintained for more 3) Grip the suction strainer stub pipe near the base
than 30 seconds. & pull it out.
After completion of the test the draft control lever 4) Clean the strainer in clean diesed fuel, using a
must be returned to the deepest position otherwise soft brush, then blow dry with compressed air and
serious damage to the hydraulic system may replace with new if necessary.
result. If the recorded pressure is not 154-168 kg/
5) Install the drain plug on hydraulic housing then
cm2. It can be increased or decreased by adding
fill the reservoir upto the slotted mark of dipstick.
or removing shims in the relief valve sping
housing. Addition of one 0.076 mm will increase 6) Run the engine for approximately for one min. this
by 3.5 Kg/cm 2 and removal of one shim will will expel the air from the system & allow the
decrease the pressure by 3.5 Kg/cm2. reservoir to be filled to capacity.
C. Draft control spring & bell crank. 7) If additional cylinders are used then add extra oil
with respected to cylinder capacity.
1. Ensure the bell crank assembly as per para 7n.
8) Install the fill plug cum dipstic.
2. Move the position control lever full forward
position.
262
3. Move draft control lever near to upper limit stop.

Hy-Tec Hydraulics
2. TROUBLE SHOOTING
Hitch does not lift either System overload Reduce load

by position control (PC) or
draft control (DC) levers Pump drive failed
a) Poor pump performance Replace pump or drive or key
(check the pump as given in 4.3)
b) Clogged suction pipe, suction Replace pump. Clean suction pipe,
strainer and suction line filter suction strainer and replace suction
line filter
c) Low oil level Fill oil to correct level.
Regulator valve malfunctioning

a) Clogging of pilot line after regulator Clean the valve body
valve.
b) Improper matching or damaged Replace the components
surfaces of seat, ball, regulator
piston
c) Spring regulating valve damaged Replace the spring
Relief valve blown before setting

a) Improper setting Replace the components
b) Relief valve spring damaged Replace the components
Compensator valve malfunctioning

a) Clogging of plug orifice Clean or replace
b) Spring compensator damaged Replace
c) Spool compensator jammed in Clean or replace
fully open position
Isolator valve closed Open isolator valve
Faulty control linkages, feedback Check the internal linkages to

lost due to linkages jammping or confirm proper feedback replace if
linkage joint disconnected required
Main spool stuck in lower position

a) Spring control valve damaged Replace the components
b) Damaged / worn out surfaces Replace the components
Hitch lifts with draft Position control feedback faulty

control but not with a) Damaged linkages or faulty joints Rectify the joints and replace the
position control of roller link, actuating link, cam, components if required
cross tube
b) Damaged position control return Replace or connect the spring.
link or disconnected spring
Hitch lifts with PC but not Draft plunger adjustment disturbed Adjust the plunger adjusting bolt. 263
with DC plunger adjusting bolt length less
than required

Hy-Tec Hydraulics
2. TROUBLE SHOOTING (Contd.)
Hitch lifts slowly Oil level in reservoir is low Fill to correct level
(Not lifting with full speed)
Fall in pump efficiency Replace or repair the Pump
Suction strainer! Suction line filter Clean strainer! replace filter

clogged
System overloaded Reduce load
Spring relief valve has taken Replace the spring

permanent set
Spring compensator damaged Replace the spring
Spring regulator valve damaged Replace the spring
Regulator piston ‘O’ ring damaged Replace ‘O’ ring

or not fitted properly
Compensator spool stuck in fully Clean or replace if required

open position.
Thermal relief valve is leaky. Replace
In draft control draft control plunger Adjust the draft control plunger
adjustment disturbed. adjusting bolt length
Implement does not reach Load movements restricted Remove restriction

maximum height
Hydraulic rock shaft, cam, lift Check & assemble properly
arms, improperly assembled
Improperly set three point Linkages Adjust
(A)
Piston oil seal or piston relief valve

Lift coming down when leaking Fit new seals or relief valve
engine is stopped jerking
when engine is running Valve or cylinder head ‘O’ ring
leaking Fit new ‘O’ ring.
Isolator valve leaky
Change ‘O’ ring
Spigot ‘O’ ring leaky
Replace
(B)
Valve parts leaking due to wear
a) Main control valve – damaged or
worn surface Check spool fit, replace
b) Check valve – damaged ball components if required.
surface, damaged ball sleeve, Check ball surface, ball seat,
264 damaged valve seat “O” ring damaged valve seat “O” ring &
replace if required.

Hy-Tec Hydraulics
Note: Close the isolator valve and if the lift arms stop falling, leakage is in control valve (See (B) above).
If the arms continue falling, leakage is in the piston (see (A) above). Unless the isolator valve is also
leaking in which case remove the valve unit and test it as given in Test Procedure.
Jerking of lift (But lift not Regulator piston ‘O’ ring worn out Replace ‘O’ ring
coming down when
engine stopped)
Hitch not lowering Main spool stuck in lift or hold Clean or replace
position
Plunger adjustment disturbed Adjust the length of adjustable bolt
External obstruction
No smooth correction in Faulty compensator assembly Clean and replace

draft control mode
Clogged orifice filter Clean and replace
Max. possible depth of Draft control plunger adjustment is Adjust the draft setting (increase
operations is less not proper. the plunger adjusting bolt length
to increase the compression and
reduce bolt length to increase
the tension range)
Less weight of implement / soil too Add weights

hard
System Overheating Air in the system Check oil level & suction pipe
connection
Water in the system Drain & refill.
Restriction in the high Remove and clean

pressure line
Relief valve continuously operating

a) Isolator valve is closed in lifting Open isolator valve
mode
b) Operating levers moved beyond Check control stop setting Check
range the linkage operation
c) Safety chain not working in DC Confirm the length of safety chain
mode (at lift condition) or replace
d) Orifice filter clogged Replace
Partial closing of regulator valve

a) Due to damaged spring regulator Replace
valve
b) Due to damaged wearing surface Replace
Pump leakage or damage Rectify or replace 265
Load movement restricted Remove restriction

Hy-Tec Hydraulics
2. TROUBLE SHOOTING (Contd.)
Noisy System Low oil level Fill to correct level
Clogged suction strainer Remove and clean
Air in the system Check oil level and suction line

joints
Load movement restricted Check for free movement of the

links and that load is not fouling
tractor
Restriction in high pressure line Remove and clean
Pipes vibrating Check the unions and tighten.
Faulty pump Repair or replace
Regulator valve not opening Position of position control stop Adjust

(oil flows through relief lever not correct
valve when lift arms are
Orifice filter choked Clean
fully raised
Regulator piston stuck in closed Remove and correct
position
Links creep up when Isolator valve not fully closed Close

working with external
Isolator valve is leaking Rectify / replace
cylinder
266

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Foreword

We are pleased to present the ‘Service Manual’ for ‘Mahindra Tractors’

Customer Care Department

Forward_Index.pmd 1 6/3/2006, 11:15 AM

SECTION DESCRIPTION PAGE

Group 2 - Engine 09-66

Group 3 - Air Cleaner & Fuel System 67-106

Group 4 - Cooling System 107-118

Group 6 - Transmission 139-184

Group 7 - Axle & Wheels 185-198

Group 8 - Brakes 199-210

Group 9 - Steering 211-220

Forward_Index.pmd 2 6/3/2006, 11:15 AM

1st Version 1st set.pmd 1 6/3/2006, 11:20 AM

A. INTRODUCTION should be used over splines and threads

1st Version 1st set.pmd 2 6/3/2006, 11:20 AM

A-9 Illustration Reference B-5 Welds

1st Version 1st set.pmd 3 6/3/2006, 11:20 AM

Why is SAFETY important to you?

1st Version 1st set.pmd 4 6/3/2006, 11:20 AM

SPECIFICATIONS FOR MAHINDRA TRACTORS

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1st Version 1st set.pmd 6 6/3/2006, 11:20 AM

1st Version 1st set.pmd 7 6/3/2006, 11:20 AM

1st Version 1st set.pmd 8 6/3/2006, 11:20 AM

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1st Version 1st set.pmd 10 6/3/2006, 11:20 AM

1st Version 1st set.pmd 11 6/3/2006, 11:20 AM

A. GENERAL 4. Unclip the main cable harness from the bottom

1st Version 1st set.pmd 12 6/3/2006, 11:20 AM

1 2c. INSTALLATION OF ENGINE :

3. Sling the engine securely. Hoist the engine into

1st Version 1st set.pmd 13 6/3/2006, 11:20 AM

2. MANIFOLDS, CYLINDER HEAD & VALVES

VALVE LEVERS, SHAFT AND BRACKETS

VALVE PUSH RODS (No.) Two per cylinder

1st Version 1st set.pmd 14 6/3/2006, 11:20 AM

3. CONNECTING RODS, PISTONS AND CYLINDER SLEEVES

1st Version 1st set.pmd 15 6/3/2006, 11:20 AM

PRESSURE REGULATING VALVE

OIL PUMP Internal rotor camshaft drivers

Type Water cool, force feed

WATER PUMP TYPE Centrifugal

6. TIMING GEAR TRAIN, FRONT COVER AND CAMSHAFT

1st Version 1st set.pmd 16 6/3/2006, 11:20 AM

Backlash between any pair of gear (mm) 0.18/0.06

1st Version 1st set.pmd 17 6/3/2006, 11:20 AM

1. Cylinder head bolts (Nm) 81 - 88

1st Version 1st set.pmd 18 6/3/2006, 11:20 AM

Chapter-2 Manifolds, Cylinder Head & Valves

1st Version 1st set.pmd 19 6/3/2006, 11:20 AM

1. DESCRIPTION 3. VALVE ROCKER ARM SHAFT ASSEMBLY

2. Exhaust Manifold Removal :

2c. CLEANING, INSPECTION & REPAIR

1st Version 1st set.pmd 20 6/3/2006, 11:20 AM

1 NOTE : Replace worn screw & nut with new

f) Check expansion plugs on both ends of the

1st Version 1st set.pmd 21 6/3/2006, 11:20 AM

Tightening sequence for 2 Cylinder Engines

1st Version 1st set.pmd 22 6/3/2006, 11:20 AM

4c. CLEANING, INSPECTION & REPAIR

1st Version 1st set.pmd 23 6/3/2006, 11:20 AM

Fig. 8 - Cylinder Head