Mahindra 60 Series User manual

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OPERATOR'SMANUAL
'60'Series
85602WD/4WD
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Tier - III Compliant

OPERATOR’S MANUAL
‘60’ Series 2WD/4WD
Model - 8560
CALIFORNIA
Proposition 65 Warning
Diesel engine exhaust and some of its constituents are
known to the State of California to cause cancer,
birth defects and other reproductive harm.
If this product contains a gasoline engine:
The engine exhaust from this product contains chemicals
known to the State of California to cause cancer,
birth defects or other reproductive harm.
The state of California requires the above two warnings.

About This Manual 5
Introduction 6
General Description 8
Owner Assistance 9
Owner’s Personal Data 10
ROPS 11
Safety Instructions 12
Safety Signs 16
Universal Symbols 20
LH and RH View of Engine 21
Lamps 22
Controls, Instruments and Operations 23
Instrument Cluster 24
RPM Meter 25
Hour Counter 25
Fuel Gauge 25
Low Fuel Warning Indicator 25
Coolant Temperature Gauge 25
High Temperature Warning Indicator 25
High Temperature Defect Indicator 26
Engine Defect Indicator 26
Engine Healthy Indicator 26
Transmission and PTO Neutral Indicator 26
Parking Brake Indicator 26
High Beam Indicator 26
Battery Charging Indicator 26
Low Engine Oil Pressure Indicator 26
Air Filter Clog Indicator 26
Turn Indicators 26
Emission Control System Indicator 26
4WD Indicator 27
PTO 540 RPM Indicator 27
Heater Indicator 27
PTO 1000 RPM Indicator 27
Service Due Indicator 27
Low Oil Pressure Indicator 27
Beeper Output 27
Self Test Function 27
Trailer Indicator 27
Buzzer for Transmission Low oil Pressure 27
Switches 28
Scuttle and Plow Lamp Switch 29
Light Switch 29
Turn Signal Switch 29
Key Switch 29
Hazard Switch 29
Horn 29
Controls 30
Operator Seat 31
Adjusting Seat Position 31
Weight Adjustment 31
Tilt Adjustment 31
Using Seat Belt 31
FastenSeat Belt31
Release Seat Belt 31
Hand Throttle Operation 32
Increasing Engine Speed 32
Engine Tachometer Speed 32
Decreasing Engine Speed 32
Constant Speed Setting 32
Foot Throttle Operation 32
Can Holder 32
Glove Box 32
Tilt Steering 33
Tilt Adjustment 33
4WD Engagement Lever 33
Brake 34
Parking brake 34
Differential Lock Pedal 35
Main and IPTO Clutch 35
IPTO Clutch 36
F-R Shuttle Shift Lever 37
Range Shift Lever 37
Speed Shift Lever 38
Auxiliary Valve 38
Loader 38
Opening the Hood 39
Closing the Hood 39
Opening Side Panels 40
Closing the Side Panels 40
Emission Control System 41
Contents
r

PTO Speed Selection 42
Hydraulic System and Operation 43
Position Control-Operation 44
Quadrant Assembly 44
Position Control 44
Position Control Lever Stop 44
Draft Control - Operation 45
Draft Control 45
Setting the Draft Control 45
Three Point Linkage 46
Toplink 46
Draft Sensing Bracket 46
Telescopic Lower Links 46
Adjustable Lift Rods 47
Lateral Stabilizers 47
Attachments 48
Swinging Drawbar 48
Adjusting Drawbar length 48
Using Swinging Drawbar 48
Attaching PTO Driven Implement 49
Jerrycan Weights 49
Wheel Weights 49
Wheel Tread Adjustment 50
Adjustment of Front Wheel Tread - 2WD 50
Adjustment of Front Wheel Tread - 4WD 51
Pneumatic Tires 52
Adding Liquid Weight 52
Inflation 52
Care of Tires 53
Shipping Tractors Equipped with 53
Pneumatic Tires
Tire Protection During Storage 53
Mounting Tires on the Rim 53
Operating Instructions 54
Before Starting The Tractor 54
Starting The Tractor 54
Cold Starting Aid 54
Glow Plug 54
Indications on Instrument Cluster 55
Driving The Tractor 56
Tractor Storage 56
Using The Tractor After Storage 56
Precautions 57
Operating The Tractor 57
The Tractor 58
Driving The Tractor 58
Servicing The Tractor 58
Operating The PTO (Power Take Off) 59
ROPS 59
Transporting Tractor on a Trailer 59
Towing 59
Diesel Fuel 59
Do’s and Dont’s 60
Maintenance 61
Cooling System 61
Radiator 61
Radiator Cap 61
Surge Tank 61
Thermostat 61
Water Pump 62
Hose Connections 62
Fan and Fan Belts 62
Draining the System 62
Cleaning Out Dirt and Sludge 62
Adding Coolant to the System 63
Cooling System Protection 63
Transmission Oil Cooler 64
Trash Guard of Transmission Oil Cooler 64
Trash Guard Radiator and Inter Cooler 64
Adjusting The Valve Clearance 65
Air Intake System 66
Air Cleaner 66
Body Air-Cleaner 66
Cyclopack or Built-in Pre-Cleaner 66
Paper Element Filter 66
Safety Cartridge 66
Dust Collector Bowl 66
Hose and Clamps 66
Fuel System 67
Clean Diesel Fuel 67
Contents

Bleeding The Fuel Filter 67
Bleeding The Fuel Injection Pump 67
Fuel Tank and Fuel Pipes 67
Tamper Proofing 67
Fuel Filter 68
Servicing The Fuel Filter 68
Lubrication System 69
Oil Level Check 69
Oil Change 69
Engine Oil Filter 69
Changing Spin On Filter 69
Turbocharger 69
Electrical System 70
Battery Maintenance Cleaning 70
Servicing 70
Effect of Low Temperatures 70
Alternator 71
Charging Circuit 71
Starter Motor Removal 71
Hydraulics and Transmission 72
Adding Hydraulic and Transmission Oil 72
Adding Oil in Rear Axle 72
Hydraulic Suction Filter and 73
Transmission Oil Filter
Hydraulics and Transmission Strainer 74
Transmission Oil Drain 74
Power Steering 75
Filling and Air Bleeding for 75
Power Steering System
Tips for maintaining the 75
Power Steering System
Front Axle - Front Wheel “Toe-in” Check 76
Preloading Bearing - 2WD 76
Clutch Pedal Free play 77
Brake Pedal Free Play 78
Head Lamp Adjustment 79
Lubricants 80
General 80
Lubricant Storage 80
Alternate and Synthetic Lubricants 80
Diesel Engine Lubricating Oil 80
Contents
Mixing of Lubricants 80
Engine Oil 81
Fluid for Power Steering 81
Transmission, Hydraulics and 82
Oil Immersed Brakes
Chassis Lubricant (CL) 82
Front Axle 82
Oil Specifications Chart 82
Special Bolt Torques 83
Specifications 84
Trouble Shooting 88
Engine 88
Turbocharger 92
Hydraulics 93
Brakes 94
Transmission 94
Rear Wheels 94
Electricals 94
Power Steering 95
Tractor History Card 96
Service Record 97
Part Replacement Record 98
Daily Operating Log 99
Tractor Storage Precautions 102
Lubrication and Greasing Chart 103
Routine Service Schedule 104
Electrical Circuit Layout 106

5
60 Series 2WD/4WD, Model - 8560
About This Manual
This Manual has been prepared to assist you in
following the correct procedure for break-in,
operation and maintenance of your new Mahindra
tractor.
Your tractor has been designed and built to give
maximum performance, with good fuel economy and
ease of operation under a wide variety of operating
conditions. Prior to delivery, the tractor was carefully
inspected, both at the factory and by your Mahindra
dealer, to ensure that it reaches you in optimum
condition. To maintain this condition and ensure
trouble free performance, it is important that the
routine services, as specified in this manual, are
carried out at the recommended intervals.
We have enclosed a page on new tractor inspection
sheets. The first sheet is the dealer’s copy and should
be removed by the dealer after the inspection has
been carried out. The second sheet is your copy of the
service performed. Ensure that you & the dealer sign
both copies.
Read this manual carefully and keep it in a convenient
place for future reference. If at any time you require
advice concerning your tractor, do not hesitate to
contact your authorised Mahindra dealer. He has
trained personnel, genuine Mahindra parts and
necessary equipments to undertake all your service
requirements.
Mahindra USA Inc’s. policy is one of continuous
improvement, and the right to change prices,
specifications or equipments at any time without
notice is reserved.
All data given in this book is subject to production
variations. Dimensions & weight are approximate only
and the illustrations do not necessarily show tractors
in standard condition. For exact information about
any particular tractor, please consult your Mahindra
dealer.

660 Series 2WD/4WD, Model - 8560
Tractor
The word, ‘Tractor’ has been derived from ‘traction’ which
means pulling. A tractor is required to pull or haul an
equipment, implement or trolley, which are coupled to the
tractor chassis through suitable linkage. A tractor can also
be used as a prime mover as it has a power outlet source
which is also called Power Take Off or PTO shaft.
In this book the operation and maintenance instructions for
8560 - 2WD/4WD model of Mahindra diesel tractors have
been compiled. This material has been prepared in detail to
help you in better understanding of maintenance and
efficient operation of the machine.
If you need any information not given in this manual, or
require the services of a trained mechanic, please get in
touch with the Mahindra dealer in your locality. Dealers are
kept informed of the latest methods of servicing tractors.
They stock genuine repair parts and are backed by the
company’s full support.
Throughout this manual, the use of the terms LEFT, RIGHT,
FRONT and REAR must be understood, to avoid any
confusion when following the instructions. The LEFT and
RIGHT means left and right sides of the tractor when facing
forward in the driver’s seat. Reference to the FRONT
indicates the radiator end of the tractor, while the REAR,
indicates the drawbar end.
Introduction
LH RH
Rear
8560 4WD
LH RH
Front
Rear
Front
8560 2WD

7
60 Series 2WD/4WD, Model - 8560
Tractor Serial No.
The tractor serial number is stamped on a plate rivetted
below the operator’s seat. For easy reference, we suggest
you to write this number in the space provided in the
owner’s personal data.
When spare parts are required, always specify the tractor
and engine serial number. This will facilitate faster delivery
and help ensure that the correct part for your particular
tractor is received.
Serial Numbers
Note the serial number of your tractor. (Punched to the
right side of engine). Always quote the serial number in any
communication to your authorised Mahindra dealer.
Introduction

860 Series 2WD/4WD, Model - 8560
General Construction
The transmission case, clutch housing, engine and
front axle are bolted together to form a rigid unit.
Engine
This tractor is fitted with fuel-efficient US EPA certified
Mahindra-NE483 TCI engine. These are turbocharged,
Intercooled, 4 cylinder, direct injection type,
comprising of rotary fuel injection pump and comply
with US Tier-III norms.
Front Axle & Wheels (For 8560 2WD)
This is a square tube design, mounted on a central
pivot pin and is having adjustable wheel track.
The front wheels are mounted on taper roller bearings
housed in a hub which itself is mounted on the
steering knuckle. The tie rod is adjustable in four
inches increments in case of three piece front axle.
Front Axle & Wheels (For 8560 4WD)
Front Axle is live front axle, with planetary reduction.
The front wheels are directly mounted on the axle.
The front track is adjustable with adjustment provided
on the rims. The turning angles are all preset.
Power Steering
The Power Steering System consists of a Hydrostatic
Steering Unit (HSU), Hydraulic cylinder, Separate
Reservoir with Return line filter and Dipstick. Rear
section of tandem pump supplies oil to this system.
Clutch
These tractors are fitted with normally disengaged
PTO dual clutch assembly, having one each 12" driven
plate for transmission drive and an independent
Power Take-Off.
Transmission
The transmission is combination type wherein the
Speed and Forward-Reverse shifting is synchromesh
whereas Range is Constantmesh.
The speed gearshift arrangement is provided on RH
side of operator’s seat. Speed gears can be operated
in 4 modes.
The range gearshift arrangement is also provided on
RH side of operator’s seat thus providing more leg-
room and comfort of operation to the operator. The
Range gears can be operated in 3 modes Viz. High,
Medium and Low.
A Forward-Reverse shuttle is provided under the
steering wheel on (LH side) the tractor. This enables to
change the direction of tractor from forward to
reverse (and vice versa) in any of the pre-selected gear
combination. This feature is helpful in application like
loader, dozer, leveler etc.
GeneralDescription
Use of Range and speed shift with F-R Shuttle shift
arrangement enables the transmission to give
12 forward & 12 Reverse speeds.
Rear Axle & Wheels
The rear axle is mounted on bearings and is enclosed
in a removable housing which is bolted to the
transmission case. The rim & disc, fitted with rear
tires, are bolted to the outer flange of rear axle. The
Rear track adjustment is provided on the rims.
Oil Immersed Disc Brakes
These are oil-immersed brakes with five discs on
either side of tractor. The actuating disc is centrally
located between two pairs of brake discs. The two
drive plates are sandwiched between two pairs. Entire
brake assembly is housed in the brake housing which
is an integral part of transmission housing. Brake
pedal and linkages actuate brake.
A parking brake lever is fitted in front of operator’s
seat.
Hydraulic System
The tractor is fitted with fully “live” Hydraulic System.
Using a pump driven directly from the Engine. It is
able to operate the three-point linkage and auxiliary
valve entirely independent of any clutch movement
when changing gear or operating the power take-off.
The Oil reservoir is common with that of transmission.
Three Point Linkages
Three Point Linkage is suitable for category 2 type
implements. For ease of implement attachment,
a sliding mechanism is provided in the lower links.
Electrical System
A 12 volt lead acid battery is used to crank the engine
with the starter motor. The electrical system is
comprised of the head lamp, scuttle lamp, side
indicator lamps, plow lamp, brake light, parking
lamp, instrument cluster, alternator and fuse box and
relays.
Safety
PTO and Transmission neutral switch are a standard
feature
Sheet Metal
Hood, Scuttle, side panels, front grille & panel,
fenders, bracketaries, including platform are
constructed of sheet metal. After undergoing through
surface preparation, it is first primed & then painted.

9
60 Series 2WD/4WD, Model - 8560
We at Mahindra USA Inc. and your Mahindra Dealer want you to be
completely satisfied with your investment. Normally any problems with
your equipment will be handled by your Dealer’s service department.
Sometimes, however, misunderstanding can occur. If you feel that your
problem has not been handled to your satisfaction, we suggest the
following:
Contact the Owner or General Manager of the dealership, explain the
problem, and request assistance. Your Dealer has direct access to the
Mahindra office. If you cannot obtain satisfaction through your Dealer,
contact the Mahindra USA Inc. office (1-800-561-9256) and provide the
following:
Your Name, Address and Telephone number
Model and Tractor Serial number
Dealer Name and Address
Tractor Purchase Date and Hours used
Nature of Problem
Before contacting Mahindra USA Inc. office, be aware that your
problem is likely to be resolved at your retail Mahindra dealership by
Dealer personnel. So it is important that your initial contact be with
your retail Mahindra Dealer.
Owner Assistance

10 60 Series 2WD/4WD, Model - 8560
Owner’s PersonalData
A metal plate having important Engine information is fitted
on the Front Cover of Engine.
Name :
Address :
Tractor Details
Model :
Tractor serial number :
Date of purchase :
Expiration of warranty :
Nearest authorised Dealer
Name :
Address :
Telephone No. :
Fax No. :
Keep this operators manual safely for regular reference. Ensure that all operators have access to it and
that they understand its contents.

11
60 Series 2WD/4WD, Model - 8560
R O P S
Roll Over Protective Structure (ROPS)
Mahindra USA Inc. tractors are fitted with a frame for the
protection of tractor operators to minimize serious operator
injury resulting from accidental roll over. These frames,
known as ROPS, form a safety zone within which the
operator is offered some protection in the event that the
tractor turns over. It is necessary that the tractor operator
fasten the seat belt around him/her to be protected by the
ROPS.
The mounting structure and fasteners forming the
mounting connection with the tractor are part of the ROPS.
(ROPS) Maintenance and Inspection
The ROPS has been certified to industry and/or government
standards. Any damage or alteration to the ROPS, mounting
hardware or seat belt voids the certification and will reduce
or eliminate protection for the operator, in the event of a
roll-over.
The ROPS, mounting hardware and seat belt should be
checked after the first 100 hrs. of machine operation and
every 500 hours thereafter for any evidence of damage,
wear or cracks. In the event of damage or alteration, the
ROPS must be replaced prior to further operation of the
machine. The seat belt must be worn during machine
operation when it is equipped with a certified ROPS. Failure
to do so will reduce or eliminate protection of the operator
in the event of a roll-over.
Substitution of mounting hardware, seat belt etc. with
components not equal to or superior to the original
certified components will void the certification and will
reduce or eliminate protection for the operator in the event
of a roll-over.
Damage of the ROPS
If the Tractor has rolled over or the ROPS has been
damaged (such as striking an overhead object during
transport), it must be replaced to provide the original
protection. After an accident, check for damages to the
1. ROPS 2. Seat 3. Seat belt & seat mountings. Before you
operate a Tractor, replace all damaged parts.
When improperly operated, a tractor can roll
over. For low clearance storage only, the roll bar
may be folded. No protection is provided when
the tractor is operated with the roll bar in the
folded position. Always raise the roll bar
immediately after low clearance storage. Always
use the seat belt when the roll bar is raised.
Seat belts save lives when they are used. Do not
use the seat belt when the roll bar is lowered.
Fold Down ROPS
Never attach chains or ropes to the ROPS for
pulling purposes; this will cause the tractor to
tip backwards. Always pull from the tractor
drawbar. Be careful when driving through door
openings or under low overhead objects. Make
sure there is sufficient overhead clearance for
the ROPS.
If the ROPS is removed or replaced, make
certain that the proper hardware is used to
replace the ROPS and the recommended torque
values are applied to the attaching bolts.
Always wear your seat belt if the tractor is
equipped with a ROPS.

12 60 Series 2WD/4WD, Model - 8560
Safety Instructions
Recognize Safety Information
This symbol means ATTENTION ! YOUR SAFETY IS INVOLVED.
The message that follows the symbol contains important
information about safety. Carefully read the message.
Signal Words
A signal word - DANGER, WARNING OR CAUTION is used
with safety alert symbol. DANGER identifies the most
serious hazards. Safety signs with signal word - DANGER OR
WARNING are typically near specific hazards.
General precautions are listed on CAUTION safety signs.
Read Safety Instructions
Carefully read all safety instructions given in this manual for
your safety. Tampering with any of the safety devices can
cause serious injuries or death. Keep all safety signs in good
condition. Replace missing or damaged safety signs.
Keep your tractor in proper condition and do not allow any
unauthorised modifications to be carried out on the tractor
which may impair the function / safety and affect tractor life.
Protect Children
Keep children and others away from the tractor while
operating.
BEFORE YOU REVERSE
• Look behind tractor for children and others.
Do not allow children to ride on tractor or any implement.
Use Of ROPS And Seat Belt
The Roll Over Protective Structure (ROPS) has been certified
to industry and/or government standards. Any damage or
alteration to the ROPS, mounting hardware, or Seat belt
voids the certification and will reduce or eliminate
protection for the operator in the event of a roll-over. The
ROPS, mounting hardware, and seat belt should be checked
after the first 100 hours of tractor operation and every 500
hours thereafter for any evidence of damage, wear or
cracks. In the event of damage or alteration, the ROPS must
be replaced prior to further operation of the tractor.
The seat belt must be worn during machine operation when
the machine is equipped with a certified ROPS. Failure to do
so will reduce or eliminate protection for the operator in
the event of a roll-over.
Precautions To Avoid Tipping
Do not drive where the tractor could slip or tip.
Stay alert for holes and rocks in the terrain, and other
hidden hazards.
Slow down before you make a sharp turn.
Driving forward out of a ditch or mired condition could
cause tractor to tip over backward. Back out of these
situations if possible.

13
60 Series 2WD/4WD, Model - 8560
Park Tractor Safely
Before parking the tractor :
Lower all equipments to the ground, bring transmission in
neutral. Engage the parking brake. Stop the engine and
remove the key.
Keep Riders Off Tractor
Do not allow riders on the tractor.
Riders on tractors subject to injury such as being struck by
foreign objects and being thrown off from the tractor.
Handle Fuel Safely — Avoid Fires
Handle fuel with care. It is highly flammable. Do not refuel
the tractor while smoking or near open flame or sparks.
Always stop engine before refueling tractors.
Always keep your tractor clean of accumulated grease and
debris. Always clean up spilled fuel.
Stay Clear of Rotating Shafts
Entanglement in rotating shaft can cause serious injury or
death.
Keep PTO shields in place at all times.
Wear close fitting clothing. Stop the engine and be sure
PTO drive is stopped before making adjustments,
connections, or cleaning out PTO driven equipment.
Always Use Safety Lights And Devices
Use of hazard warning lights and turn signals are
recommended when driving the tractor on public roads
unless prohibited by state or local regulations.
Use slow moving vehicle (SMV) sign when driving on public
road during both day & night time, unless prohibited by
law.
Safety Instructions

14 60 Series 2WD/4WD, Model - 8560
Service Tractor Safely
Do not wear a necktie, scarf or loose clothing when you
work near moving parts. If these items were to get caught,
severe injury could result.
Remove rings and other jewellery to prevent electrical
shorts and entanglement in moving parts.
Practice Safe Maintenance
Understand service procedure before doing work. Keep the
surrounding area of the tractor clean & dry.
Do not attempt to service tractor when it is in motion. Keep
body and clothing away from rotating shafts. Always lower
equipment to the ground. Stop the engine. Remove the key.
Allow tractor to cool before any work/repair is performed
on it.
Securely support any tractor components that must be
raised for service work.
Keep all parts in good condition and properly installed.
Replace worn or broken parts. Replace damaged or missing
decals. Remove any buildup of grease or oil from the
tractor.
Disconnect the battery ground cable (-) before making
adjustments on electrical systems or welding on tractor.
Prevent Acid Burns
Sulfuric acid in battery electrolyte is poisonous. It is strong
enough to burn skin, cause holes in clothing and cause
blindness if it contacts the eye.
For adequate safety always :
1. Fill batteries in a well-ventilated area.
2. Wear eye protection and acid proof hand gloves.
3. Avoid breathing direct fumes when electrolyte is added.
4. Do not add water to electrolyte as it may splash off
causing severe burns.
If you spill acid on yourself :
1. Flush your skin with water.
2. Flush your eyes with water for 10-15 minutes. Get
medical attention immediately.
Prevent Battery Explosions
Keep sparks, lighted matches, and open flame away from
the top of battery. Battery gas can explode.
Never check battery charge by placing a metal object across
the poles.
Safety Instructions

15
60 Series 2WD/4WD, Model - 8560
Avoid High-pressure Fluids
Escaping fluid under pressure can penetrate the skin
causing serious injury. Keep hands and body away from
pinholes and nozzles which eject fluids under high pressure.
Do not operate Auxiliary valve when terminal pipes are
open.
If ANY fluid is injected into the skin. Consult your doctor
immediately.
Work In Ventilated Area
Do not start the tractor in an enclosed building unless the
doors & windows are open for proper ventilation, as tractor
exhaust fumes can cause sickness or death. If it is necessary
to run an engine in an enclosed area remove the exhaust
fumes by connecting exhaust pipe extension and drawing
them out with an exhaust fan.
Slow Moving Vehicle Emblem
Observe the following precautions when operating the
tractor on road.
1. Ensure that Slow Moving vehicle (SMV) emblem (A)
affixed on back side of operator seat is clean and visible.
2. If towed or rear-mounted equipment obstructs this
emblem, install SMV emblem on equipment.
Tractor Runaway
Avoid possible injury or death from possible runaway.
Do not start the engine by shorting across electrical
circuit. The tractor will start in gear if starting circuit is
bypassed.
NEVER start engine while standing on ground. Start
engine only from operator’s seat with, transmission in
neutral position, hand brake lever engaged and PTO
lever in disengaged position.
The tractor can start only if the transmission is in neutral
position and PTO lever in neutral as well.
For additional safety keep, the engine starting key in OFF
position, transmission in neutral position, hand brake
lever engaged, PTO lever in disengaged position while
servicing the tractor.
Safety Instructions
A

16 60 Series 2WD/4WD, Model - 8560
Safety Signs

17
60 Series 2WD/4WD, Model - 8560
Safety Signs

18 60 Series 2WD/4WD, Model - 8560
Safety Signs

19
60 Series 2WD/4WD, Model - 8560
Safety Signs
*
*- Applicable for 8560 4WD