Mahindra Jivo 245 DI User manual

SERVICE MANUAL

INDEX
Sr. No. Descripon Page No.
GENERAL
1Product Specicaon 5-6
2Safety Notes 7
MAINTENANCE
3Maintenance Chart 9
4Special Service Tools List 10
5Special Service Tools Details
AEngine 11
BTransmission 12-13
C 4 WD Front Axle 14-15
6Fault Tracing 16
7Greasing Point Locaon 17
8Consumable Details 18
9Primary Check Up 19
10 Bleeding Fuel System 20
11 Tyre Maintenance 21
12 Front Wheel Toe - In 22
13 Front Wiring Harness Layout 23
14 Rear Wiring Harness Layout 24
TRANSMISSION - 4WD FRONT AXLE
15 4wd Front Axle -Torque Values 26
16 Bearing & Oil Seal Posion 26
17 Maintenance Schedule On 4wd Front Axle 27
18 4wd Front Axle –Oil & Grease Specicaons 28
19 Swivel & Side Housing Sub Assembly
AHub End -Assembly Process 29-31
BSwivel Housing Sub Assembly 32
C Side Housing Sub Assembly Lh & Rh 33
D Swivel To Side Housing Assembly 34
20 Dierenal Assembly 35
21 Spline Sha Assembly 36-38
22 Beam Housing Assembly 39-40
23 Crical Seng On 4wd Front Axle Chart 41

INDEX
Sr. No. Descripon Page No.
TRANSMISSION
24 Transmission Torque Values 43
25 Bearing and Oil Seal Posions 43
26 Transmission Oil & Greassing Locaons 44
27 Transmission Slidingmesh Gears And Shas Layout 45-46
28 Speed Boom Sha Mounng 47
29 Speed Housing Fork & Rail Mounng 48
30 Speed Shier Assembly & Mounng 49-50
31 Speed Driving Sha Mounng 51
32 Cluster Gear Mounng 52
33 Input Sha Mounng 52
34 Speed Housing And Clutch Housing Assembly 53
35 Rear Axle Carrier Assembly & Mounng Process 54-55
36 Bevel Pinion Sha Sub Assembly 56
37 Bullcage & Dierenal Assembly 57-59
38 Brake Assembly Mounng 60
39 Dropbox Assembly & Mounng On Rear Housing 61
40 Speed Housing And Clutch Housing Mounng With Rear Housing 61-62
41 Speed Shier Assembly & Mounng 63
42 1 Speed Pto Sha And Gears Assembly And Mounng 64
43 1 Speed Pto Operang Linkage Mounng 65
44 Range Shier Assembly & Mounng 66
45 Reverse Idler Sha Assembly And Mounng 67
46 Transmission Covers Mounng 68
ENGINE
47 Detailed Engine Specicaons 70
48 Engine Torque Chart 71-74
49 Recommended FIP Removal Instrucon 75
50 Recommended FIP Mounng Instrucon 76
51 Cylinder Head Bolt Torquing Sequence 77
52 Tappet Sengs 77
53 Relling of Coolant In System 78
54 Engine Trouble Shoong 79-87

GENERAL

PRODUCT SPECIFICATION
GENERAL 5
MAHINDRA JIVO 245DI
ENGINE
Type Mahindra - MDI 1365 NX24
No. of Cylinders 2
Engine Power 20 H.P. & 24 H.P.
Bore 88.9
Stroke 110
Displacement CC 1366
Rated Governed Speed 2300 ± 50
Low Idle R.P.M. 900 ± 50
High Idle R.P.M. 2550 ± 50
Air Cleaner Dry type
Cooling System Forced circulaon of coolant
CLUTCH
Clutch Type 8” Dry fricon plate
TRANSMISSION
Type Mechanical, Sliding Mesh
No of Gears 8 Forward & 4 Reverse
Power Take O Rear mounted six splines, Non - CRPTO - 540 R.P.M & 540 E as Opt.
PTO rpm at rated engine speed 605 & 750
Brakes Mechanical dry disc type and oil Immersed brakes (OIB)
HYDRAULICS
Type Hytech Hydraulics. Fully live Hydraulic with Posion & Dra Controls
Liing Capacity (Kgs) 450 at Frame and 750 at Hitch
TRACTOR
Steering Type Worm & Roller - for Mechanical Steering and Hydrostac Steering
Tyre Size Front 6.0 x 14 (4WD) - 6 PR, 5.2 x 14 (2WD)
Tyre Size Rear 8.3 x 24 - 6 PR
CAPACITIES (litres)
Engine (including lter) 4
Cooling System (Approx) 5.7
Fuel Tank 22
Transmission & Hydraulic System 19 (Dry brake & Mech. Steering), 23 (PS + OIB)
Total weight of Tractor Without Ballast (KG) 1000
TRACTOR DIAMENSIONS (mm)
Overall Height (mm) 1373
Overall Length (mm) 2746
Ground Clearance (mm) 285
Overall Width (mm) 1130
Wheel Base (mm) 1570
Front Track Width (mm) 864 Std
Rear Track Width (mm) 762 to 915

PRODUCT SPECIFICATION
GENERAL 6

PRODUCT SPECIFICATION
GENERAL
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7
SAFETY - ALERT SYMBOL AND TERMS
Why is SAFETY important to you?
ACCIDENTS DISABLE AND KILL
ACCIDENTS ARE COSTLY
ACCIDENTS CAN BE AVOIDED
This Safety Alert Symbol means ATTENTION! BE ALERT! YOUR SAFETY IS INVOLVED!
The safety alert symbol idenes important safety messages on machines, safety signs, in manuals, or
elsewhere. When you see this symbol, be alert to the possibility of personal injury or death. Follow the
instrucons given in the safety messages.
Remember that YOU are the key to safety. Good safety pracces not only protect you, but also the people
around you. Study the features in this manual and make them a working part of your safety program. Keep
in mind that this safety secon is wrien only for this type of machine. Pracce all other usual and cus-
tomary
safe working precauons, and above all - REMEMBER - SAFETY IS YOUR RESPONSIBILITY. YOU ONLY CAN
PREVENT SERIOUS INJURY OR DEATH.
SAFETY - DANGER, WARNING and CAUTION
Whenever you see the words and symbols shown below, used in this book and on decals, you MUST take
note of their instructions.
The symbol and the word DANGER indicates an imminently hazardous
situaon with, if not avoided, will result in DEATH OR SERIOUS INJURY.
The symbol and the word WARNING indicates a potenally hazardous
situaon. If the instrucons or procedures are not correctly followed it
could result in PERSONAL INJURY, OR LOSS OF LIFE.
The symbol and the word CAUTION idenes special instrucons or
procedure which if not strictly observed, could result in DAMAGE,
DESTRUCTION OF EQUIPMENT, OR PERSONAL INJURY.
The word NOTE indicates points of parcular interest for more ecient and
convenient repair or operaon
DANGER :-
WARNING :-
CAUTION :-
NOTE :-

MAINTENANCE

MAINTENANCE
Details Activity To be done by Operator
10 Hrs/ Periodic 100 Hrs 350 Hrs 600 Hrs 850 Hrs
Tractor
Tractor Cleaning & washing Do  
Grease all Nipples Do  
Toe- In (4WD & 2WD) Check 
All Visible Nuts & Bolts Tighten  
Oil Leakages Check & rectify  
Engine
Oil Level Check  
Oil (API CH4/SAE 15W40/ Mahindra M-Star) Change 
Oil Filter Change 
Valve Clearance (Tappet Setting) Check 
Low-Hi Idle Engine R.P.M. Check 
Power, Response & Exhaust Smoke Check 
Cylinder Head bolt torque Check 
Air Cleaner
Pre-cleaner* Clean  
Air Cleaner Connections Check  
Fuel System
Fuel Filter Change 
Injector Check 
Transmission
Oil level Check  
Oil (Common Transmission & Hydraulic)
Grade :EP-90 (Dry Brakes)/Mahindra M-Star
Oil (OIB)
Change
Cooling System
Thrash Guard Clean  
Radiator Fins Clean  
Coolant - Water Check & Top Up  
Fan Belt & Fan Belt Tension Check & Correct  
Hydraulics
Suction Filter Change 
Suction Strainer Clean
Battery Electrolyte Level Check  
Battery Terminals Clean  
Battery Vent Plug Holes Clean  
Alternator Belt & Alternator Belt Tension Check  
Instruments & Gauges Check 
Light & Horn Check 
Clutch
Free Play Check 
Brakes
Free Play Check 
Breather Check 
Tyre
Air Pressure Check  
Steering Gear Box (Mechanical Bold Steering)
Change
Oil Level Check  
Front Axle
Front Wheel Bearing Pre-load Check 
Stay Rod Ball Joint Check 
Front Axle (4WD)
Oil Level Check  
Toe - in (3 to 5 mm) Check & Set  
Oil (80 W 90 GL5) Change
To be done by Dealer Technician
1100 hrs.
Oil to be change at 850 hrs.
Oil to be change at 850 hrs.
* - Air cleaner primary element to be cleaned only after indication of its chocking. Air cleaner element to be changed after three cleaning Or
850 hrs.
9
MAINTENANCE CHART

SPECIAL SERVICE TOOL PART LISTS
MAINTENANCE CHART
MAINTENANCE
Type Quantity in litres Grade Change Frequency
Fuel Tank 22 NA NA
Engine Oil 4
API CH4 / SAE 15W40 /
Mahindra M star Genuine Oil
Every Service
Transmission Oil
23 (OIB + PS), 19 (Dry
Brake Mech. Steering)
EP 90 (Dry Brake) / Mahindra
MStar Transmission oil (OIB)
850 Hrs
Front Axle 4WD 580 W 90 GL5 850 Hrs
Cooling System 5 (20HP) & 6 (24HP) Redimix Coolant 1000 Hrs
Sr. no. Tool No Tool Description Aggregate
1AGENYNH0061 Protective sleeve Rear Oil seal Engine
2AGENYNH0054 Rear Oil seal Dolly Engine
3AGTNYNH0092 Crimping Tool for Spline Shaft Transmission
4AGTNYNH0101 Dolly Oil Seal drop box retainer Transmission
5AGTNYNH0016 Dolly for Rear axle Oil Seal Retainer Transmission
6AGTNYNH0038 Dolly for Oil Seal Pressing Input Shaft Retainer Transmission
7AGTNYNH0013 PTO oil seal Dolly Transmission
8AGTNYNH0069 Slip Gauge for CCD Transmission
9AGTRYNH0001 Clutch centralizer Tractor
10 AGFAYNH0001 Oil Seal Press Dolly Beam Housing 4WD
11 AGFAYNH0053 Sninger Top Seal Fitment 4WD
12 AGFAYNH0037 Spline Shaft Crimping Nut Torque 4WD
13 AGFAYNH0001 Oil Seal Press Dolly Beam Housing 4WD
14 AGFAYNH0034 Dolly for Swivel Housing Oil Seal Pressing 4WD
15 AGFAYNH0034 Dolly for Swivel Housing Oil Seal Pressing 4WD
16 AGFAYNH0049 Sninger Bottom Seal Fitment 4WD
17 17 No allen key Special ratchet for Drain Plug 4WD axle 4WD
4WD Axle Tools
Engine SST
Transmission Tools
10

SPECIAL SERVICE TOOL DETAILS
MAINTENANCE
1 AGENYNH0061 2 AGENYNH0054
Dolly for ywheel housing oil seal pressing-
Use of this dolly will ensure proper tment
of seal in housing and will avoid repeat seal
leakages
PROCEDURE TO USE TOOL
1 2
3 4
Place the oil seal on the dolly Hammer seal with the help of dolly
Assemble the oil seal on the dolly Aer pressing the oil seal remove dolly
Protecve sleeve
for ywheel hous-
ing inseron in
crank sha.
It is essenal to
use protecve
sleeve to avoid
damage of seal
while assy.
11

SPECIAL SERVICE TOOL DETAILS
MAINTENANCE
3 AGTNYNH0092 PROCEDURE TO USE TOOL
4 AGTNYNH0101
5 AGTRYNH0016
Place the oil seal on the dolly
Use tool to ghten lock nut on Spiral Bevel Sha
with torque wrench. Torque value-: (80-90) Nm
PROCEDURE TO USE TOOL
PROCEDURE TO USE TOOL
Hammer seal with the help of dolly
Place oil seal
in rear axle
casing.Then
using the tool
AGTRYNH0016
and ham-
mer press the
oil seal in it
12

SPECIAL SERVICE TOOL DETAILS
MAINTENANCE
6 AGTNYNH0038 PROCEDURE TO USE TOOL
7 AGTNYNH0013
9 AGTRYNH0001
Dolly for oil seal pressing in PTO housing plate
AGTNYNH0069
PROCEDURE TO USE TOOL
Gauge for checking CCD between bevel pin-
ion and di. case
Place oil seal
in Input Sha
Retainer. Then
using the tool
AGTNYNH0038
and ham-
mer press the
oil seal in it
Tool for centralizing the clutch properly
Insert tool in cranksha & then pass clutch
through it and x it with bolts.
8
13

SPECIAL SERVICE TOOL DETAILS
MAINTENANCE
10 AGFAYNH0001
1PROCEDURE TO USE TOOL
2PROCEDURE TO USE TOOL
11 AGFAYNH0053
12 AGFAYNH0037
PROCEDURE TO USE TOOL
Dolly for pressing slinger and bearing in
housing
Place slinger on dolly & assemble bearing on
it
Dolly for
pressing slinger in
side housing
Insert dolly with sub assy inside Swivel
Housing
ToolforSpiralPinionshacrimpingnut
UsetooltoghtenlocknutonSpiralBevel
Shawithtorquewrench.Torquevalue-:
(80-90)Nm
14

SPECIAL SERVICE TOOL DETAILS
MAINTENANCE
13 AGFAYNH001 PROCEDURE TO USE TOOL
14 AGFAYNH0034
15 AGFAYNH0031
Assemble bearing and oil seal on dolly
Place oil seal in beam housing and press
with tool
PROCEDURE TO USE TOOL
Dolly for pressing oil seal in beam housing
Insert Dolly
AGFAYNH0034
with sub
assembly of
oil seal and
bearing inside
Swivel Housing
Dolly for hub end oil seal pressing
15

FAULT TRACING
MAINTENANCE
Probable cause Possible remedy
Engine not starng
Stopper knob pulled out Push the knob in
Water in fuel Drain system, clean and rell with proper fuel
Fuel system choked Replace Fuel Filter, Check and Clean dirt in tank
Baeries discharged Charge or replace
Air cleaner choked Clean air cleaner
Air trapped in fuel lines Remove air from fuel lines, injector and fuel lter by
loosening of went plug. Do not forget to re-ght it.
Excessive oil consumpon
Oil level in crankcase too high Maintain correct oil level
Oil leaking Recfy leakage
Crankcase breather clogged Wash in breather mesh petrol, blow dry and replace
Engine overheats
Insucient water in the cooling system Check water level in radiator and top up if necessary
Cooling system clogged Clean out radiator & water jackets of engine
Insucient oil Top up and maintain proper oil level
Brakes dragging Check brake linkages for free movement and adjust free
pedal play
Belt Slippage Check belt tension and correct it
Injector Clogged Check nozzle opening pressure and Corrected it
Air cleaner choked Remove check & clean
Improper grade / impuries in Fuel Use correct grade of fuel
Excessive fuel consumpon
Fuel leaks Tighten or replace fuel lines / Banjo Washer
Engine overloaded Select the gear w.r.t load, speed
Engine not operang at proper temperature Check cooling system and thermostat.
Hydraulics - no liing or slow liing
Less/No oil in system Check & ll oil to correct level.
Hydraulic lock valve closed Open valve.
Hydraulic pump has lost its eciency Get the pump replaced.
Control valve defecve See Mahindra Tractor Dealer / Authorized Service
Centre,
Control linkage defecve See Mahindra Tractor Dealer / Authorized Service
Centre,
System overloaded Reduce load on system.
Brakes
Do not hold or slips Adjust brakes or change linings if needed. Lining’s oiled
up; check bull pinion sha oil seal.
Drag or uneven Adjust brakes.
Return spring broken Replace
Will not release Release hand-brake. Check brake sha for seizure.
16

GREASING POINTS LOCATIONS
MAINTENANCE 17
Sr. No Locaon Greasing Points
1Front & Rear Pillow Block 2
24WD King Pin Spindle 2
3 Clutch Pedal & Brake Pedal
2
2
4Range Shier lever 1
5Bell Crank Assembly 1
6PTO Lever 1
7Clutch Sha & Clutch Release
Bearing Sleeve
1
1
8Tie Rod (Mech. + PS Steering) &
Steering Knuckle Arm
2
2

CONSUMABLE DETAILS
MAINTENANCE 18
Engine Coolant Specs. Hydraulic Oil Filter Specs. Engine Oil Filter Specs.
Coolant Grade- Redimix
Coolant Oil Filter Changed-
1st at 100 Hrs.
& then
Every 250 Hrs.
Oil Filter Changed-
1st at 100 Hrs.
& then
Every 250 Hrs.
Coolant Quanty-
5 Ltr(20HP) & 6 Ltr (24HP)
Coolant Change Period-
Every 1000 Hrs.
4WD Front Axle Oil
Specs. Engine Oil Specs. Fuel Filter Specs. Transmission Oil Specs.
Oil Grade-
SAE80W90GL5
Oil Grade-
API CH4 / SAE 15W40 /
Mahindra M star
Genuine Oil
Fuel Filter Changed-
1st at 350 Hrs.
& then
Every 250 Hrs.
Oil Grade-
EP-90 (Dry Brakes)/
Mahindra M-Star Oil
(OIB)
Oil Quanty- 5.0 Liters Oil Quanty- 4.0 Liters
Oil Quanty-
23 Ltr (OIB + PS), 19 Ltr
(Dry Brake +Mech.
Steering)
Oil Change Period -
1st at 850 Hrs. &
thenEvery 1000 Hrs.
Oil Change Period -
Every Service
Oil Change Period -
Every 850Hrs.

PRIMARY CHECK UP
MAINTENANCE
1
2
3
Checking Engine Oil Level
• Check the engine oil before starng the engine or ‘5’ minutes or more
aer the engine has stopped.
• To check the oil level, draw out the dipsck, wipe it clean, insert it and
draw it out again. Check to see that the oil level lies between the two marks.
• Add oil only when the oil level reaches the lowest mark.Recommended oil
-“Mahindra M-Star Genuine Engine Oil / API CH-4 SAE 15W40 Oil
CAUTION -:Do not run the engine if the oil level is low than specied.
Checking Coolant Level
• Check coolant level in recovery
bole & Top-up if required.
• Use redimix coolant for top up.
WARNING -: Do not open the
coolant cap when
the engine is hot. Do
not remove the
radiator cap when
the engine is hot
Checking radiator ns
• Clean cha guard daily or earlier if chocked.
• Blow compressed air through the radiator ns to remove foreign material
NOTE -: Radiator ns must be free of dust or cha to prevent the
engine from overheang.
CAUTION -: To avoid personnel injury, ensure to stop the engine
before working on radiator.
4 5
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Check clutch pedal
• With clutch fully engaged pedal should have
free movement of 20 – 25 mm
Check brake pedal
• Pedals should have free movement of 25-30 m.
19
Checking fan belt tension
The tension is correct when the belt can be pressed
by thumb to 9 - 12 mm.midway between the two
pulleys without much eort.
In case the
tension is not
correct the
adjust the
tension by
adjusng
alternator
posion on
brace plate.

BLEEDING FUEL SYSTEM
MAINTENANCE
PROCEDURE OF BLEEDING AIR FROM FUEL SYSTEM
Air must be removed :
1) When the fuel lter or lines are removed.
2) When water is drained from fuel lter.
3) When tank is completely empty.
4) When tractor is not used for a long period of me
Make sure that fuel
Pipe clips are
ghten.
Open the air vent
on the fuel injecon
Pump.
Pump the fuel pump
knob located on the top
of the fuel lter.
The fuel pump knob will
pump easily at rst and
with added resistance
as air is purged from the
system.
To make sure air is com-
pletely purged, pinch
the fuel over ow hose
with ngers if a pulsa-
on is le when the
knob is pumped then,
no air remain
(1) Set the hand throle lever / accelerator at maximum
speed posion.
(2) Turn on the key switch to start the engine and then
reset the throle at the mid speed posion.
If engine doesn’t start try it several mes with 30 seconds
Intervals
Accelerate the engine to remove the small posion of air
in the fuel system.
If the air sll remains and the engine stops, repeat the
above steps.
Close the air vent.
CAUTION :-
Do not hold key at engine start posion for more than 10 seconds connuously. If more
engine cranking is needed try again aer 30 seconds.
Always close the air vent screw except for bleeding fuel lines other wise, engine will run
irregularly or stall frequently.
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20