Mahindra Jivo 365 DI User manual

1
Mahindra
Jivo 365 DI
SERVICE MANUAL

2
Sr. No
Description
Page No
General
1
Product Specifications
1 –3
2
Safety Notes
4
Maintenance
3
Maintenance Chart
6-8
4
Special Service Tools
9
5
Greasing Points Locations
10
6
Consumable Details
11
7
Primary Check up
12
8
Tyre Maintenance
13 - 15
Engine
9
Engine Specifications
17-22
10
Torque Chart
23-25
11
Manifolds & Cylinder Head
27-40
12
Timing Gears, Camshaft & Front Plate
42-48
13
Connecting Rods, Pistons & Cylinder Liners
50-61
14
Engine Assembly
62-86
15
Troubleshooting
88-92
Index

1
ENGINE
Type
Mahindra MDI
No of Cylinders
3
Engine Power
36 HP
Bore
88.9
Stroke
110
Displacement CC
2048
Rated Governor Speed
2600
Low Idle RPM
850 ± 50
High Idle RPM
2850 ± 50
Air Cleaner
Dry Type
Cooling System
Forced Circulation of Coolant
Clutch
Clutch Type
9.5” Dry Friction Plate
TRANSMISSION
Type
Forward Reverse –Synchro
Speed –Constant
Range –Sliding
No of Gears
8 Forward & 8 Reverse
Power Take Off
Rear mounted Six Splines, 590 & 845 @ 2600 erpm
PTO RPM at Rated Engine Speed
590 & 845 @ 2600 erpm
Brakes
Mechanical Dry Disc Type Oil Immersed Brake (OIB)
HYDRAULICS
Type
Fully Live Hydraulic with Position & Draft Controls
Lifting Capacity (Kgs)
900 @ Hitch
TRACTOR
Steering Type
Power Steering
Tyre Size Front
Vineyard - 152 X 305 mm (6.0 x 12 inch) 4 PR
Paddy - 203 X 406 mm (8.0 x 16 inch) 4 PR
Tyre Size Rear
Vineyard - 241 X 508 mm (9.5 x 20 inch) 6 PR
Paddy - 315 X 610 mm (12.4 x 24 inch) 6 PR
CAPACITIES (Litres)
Engine (Including Filter)
6.5
Cooling System (Approx)
5.7
Fuel Tank
Vineyard - 25
Paddy - 35
Transmission & Hydraulic System
31
Total Weight Of Tractor Without Ballast (Kg)
Vineyard - 1213
Paddy - 1450
Mahindra Jivo 365
PRODUCT SPECIFICATION

2
TRACTOR DIMENSIONS (mm) - Vineyard
Overall Height
1305 ± 20
Overall Length
3050 ± 20
Ground Clearance
196 ± 20
Overall Width
"Front - 1200 ± 20, Rear - 1245 ± 20"
Wheel Base
1650
Front Track Width
1040 ± 20
Rear Track Width
1010 ± 20
PRODUCT SPECIFICATION

3
TRACTOR DIMENSIONS (mm) - Paddy
Overall Height
1405 ± 20
Overall Length
3050 ± 20
Ground Clearance
306 ± 20
Overall Width
"Front - 1305 ± 20, Rear - 1410 ± 20"
Wheel Base
1650
Front Track Width
1115 ± 20
Rear Track Width
1095 ± 20
PRODUCT SPECIFICATION

4
PRODUCT SPECIFICATION

5
MAINTENANCE

6
Preventive Maintenance Schedule
Details
Activity
To be done by
Operator
To be done by Dealer
Technician
10 Hrs /
Periodic
100
Hrs
350
Hrs
600
Hrs
850
Hrs
Tractor
Tractor Cleaning & washing
Do





Grease all Nipples
Do





Toe- In
Check





All Visible Nuts & Bolts
Tighten





Oil Leakages
Check &
rectify





Engine
Oil Level
Check





Oil M- Star Premium
Change





Oil Filter
Change





Valve Clearance (Tappet Setting)
Check





Low-Hi Idle Engine R.P.M.
Check





Power, Response & Exhaust
Smoke
Check





Belt Tension
Check & Set





Air Cleaner
Primary Element*
Clean /
Change




Change
Safety Cartridge
Clean /
Change
Hose Connections
Check





Fuel System
Fuel Filter
Change



Injector
Check



* - Air cleaner primary element to be cleaned only after indication of its chocking. Air cleaner element to be
changed after three cleanings or at 850 Hrs. Safety Cartridge not to clean.
MAINTENANCE CHART

7
Preventive Maintenance Schedule
Details
Activity
To be done by
Operator
To be done by Dealer
Technician
10 Hrs /
Periodic
100
Hrs
350
Hrs
600
Hrs
850
Hrs
Transmission
Oil level
Check





Oil (Common Transmission &
Hydraulic), Grade: 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




Electrical System
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




Rubber Boot
Check




Working Of Hand Brake
Check




MAINTENANCE CHART

8
Preventive Maintenance Schedule
Details
Activity
To be done by
Operator
To be done by Dealer
Technician
10 Hrs /
Periodic
100
Hrs
350
Hrs
600
Hrs
850
Hrs
Tyre
Air Pressure
Check





Front Axle
Front Wheel Bearing free play*
Check




Front Axle (4WD)
Oil Level
Check




Toe - in (3 to 5 mm)
Check & Set




Oil (80 W 90 GL5)
Change




MAINTENANCE CHART

9
Kit Part No 00000030071K
Sr. No
Tool No
Tool Description
Aggregate
1
MST-9A01-FA-101
Front Axle King Pin Seal Dolly
4WDFront Axle
2
MST-9A01-TN-102
Main Shaft Oil Seal Pressing Tool
Transmission
3
MST-9A01-4W-103
4WD Pinion Check Nut Loosening Tool
4WDFront Axle
4
MST-9A01-FA-104
Power Cylinder Check Nut Loosening Tool
Tractor
5
MST-9A01-EN-105
Dummy Injector
Engine
6
MST-9A01-EN-106
Crankshaft Rear Oil Seal Retainer
Engine
7
MST-9A01-TN-107
Shaft
Transmission
MST-9A01-TN-107 (1)
Washer
MST-9A01-TN-107 (2)
Nut
MST-9A01-TN-107 (3)
Shaft
MST-9A01-TN-107 (4)
Flange
8
MST-9A01-EN-108
FIP Removal Tool
Kit Part No 0000003016TK
Sr. No
Tool No
Tool Description
Aggregate
1
MST-9A01-FA-108
Front Axle CCD
4WD Front Axle
2
MST-9A01-FA-109
Cover Bearing Stack Height
4WD Front Axle
3
MST-9A01-FA-110
Cover Bottom End Play
4WD Front Axle
4
MST-9A01-FA-111
Holder Top End Play
4WD Front Axle
SPECIAL SERVICE TOOLS

10
GREASING POINTS LOCATIONS

11
Type
Quantity In litres
Grade
Change Frequency
Engine Oil
6.5
Mahindra M Star Premium
Every Service
Transmission Oil
31
Mahindra M Star Genuine OIB
Oil / Servo M Trac 30
Every 850 Hours
Front Axle ( 4WD)
3.7 –Vineyard
4.0 –Paddy
Servo M Trac 30
1st at 100 & then at
every 850 hours
Cooling System
5.7
Mahindra M Star Coolz or
Coolant Confirming to JIS K -
2234
800 hours
Fuel Tank
25 –Vineyard
35 –Paddy
NA
NA
CONSUMABLE DETAILS

12
PRIMARY CHECKUP
Checking Engine Oil Level
Check the engine oil before starting the engine or ‘5’
minutes or more after the engine has stopped.
To check the oil level, draw out the dipstick, 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.
Caution -Do not run the engine if the oil level is low than specified.
1
Checking Coolant Level
Check coolant level in recovery bottle & 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
2
Checking Radiator Fins
Clean chaff guard daily or earlier if chocked.
Blow compressed air through the radiator fins to
remove foreign material
Caution -To avoid personnel injury, ensure to stop the engine before
working on radiator.
3
Checking Radiator Fins
The tension is correct when the belt can be pressed by
thumb to 9 - 12 mm. midway between the two pulleys
without much effort.
In case the tension is not correct then adjust the tension
by adjusting alternator position on brace plate.
4

13
TYRE MAINTENANCE
Checking tyre pressure
For normal load and operation of the tractor the following tyre pressure is recommended.
Operation
Puddling
Vineyard
Front Tyre
8 x 16
Rear Tyre
12.4 x 24
Front Tyre
6 x 12
Rear Tyre
9.5 x 20
Field
1.60 kg/cm² (23)
1.60 kg/cm² (23)
1.3 kg/cm² (19)
1.2 kg/cm² (17)
Road
1.60 kg/cm² (23)
1.60 kg/cm² (23)
2.0 kg/cm² (29)
1.4 kg/cm² (20)
Note:
1. Keep the tube valve always closed with the dust cap, to protect the valve from mud/dust/slush.
2. To achieve best performance and maximum tyre life, maintain air pressure as per tyre size and
load carrying capacity as recommendation.
Addition of Wheel Weights At Rear –To increase drawbar pull of the tractor & reduce wheel slip
(Increase tyre life)
Cast Iron weights can be attached to the rear driving wheels.
In case the slip continues, it may be necessary to liquid ballast the tyre.
Adding Water:
Tractor tyre can be 80% filled with water as follows, Remove excess air from Tyre.
1. Remove all air from tyre.
2. Raise the wheel. Rotate the tyre until the valve, stem is at 1’O Clock position.
3. Remove the valve core housing and screw on the adapter.
4. Force water into the tyre from a tank placed at least five feet higher than the tractor tyre, or by
using a compressor and pressure tank filled with water.
5. When the liquid has reached the required level, remove the adapter, screw in the valve core and
inflate to the recommended pressure.
6. Maintain air pressure as per recommendation.

14
TYRE MAINTENANCE
Front Axle - Front Wheel “Toe In Check”
In the event of the tie rod setting being interfered with, then it is necessary to adjust the TOE-IN.
Before measuring and adjusting the TOE-IN, ensure the front wheels are in the straight ahead
position and the front axle is not tilted. Calculation of Toe In-: (Refer image TOE-IN ADJUSTMENT)
Measure distance between centres of both front wheels from front of tractor. Let that distance be
“Y”. Now adjust track rod ball joints such that distance” will remain same in front side of front
wheels and at rear side of front wheel distance will increase in 4 to 6 mm. let distance let distance
in rear of Front wheel be “X”. Therefore X= (Y+4) To (Y+6) in mm
Toe In Adjustment
Procedure To Adjust Toe In-:
Loosen check nut of wheel cylinder from both sides and adjust Toe in position of front wheel.
While adjusting position maintain centre of ram in wheel cylinder with exact centre of Front axle
position.

15
TYRE MAINTENANCE
Front Axle - Front Wheel “Toe In Check”
In the event of the tie rod setting being interfered with, then it is necessary to adjust the TOE-IN.
Before measuring and adjusting the TOE-IN, ensure the front wheels are in the straight ahead
position and the front axle is not tilted. Calculation of Toe In-: (Refer image TOE-IN ADJUSTMENT)
Measure distance between centres of both front wheels from front of tractor. Let that distance be
“Y”. Now adjust track rod ball joints such that distance” will remain same in front side of front
wheels and at rear side of front wheel distance will increase in 4 to 6 mm. let distance let distance
in rear of Front wheel be “X”. Therefore X= (Y+4) To (Y+6) in mm
Toe In Adjustment
Procedure To Adjust Toe In-:
Loosen check nut of wheel cylinder from both sides and adjust Toe in position of front wheel.
While adjusting position maintain centre of ram in wheel cylinder with exact centre of Front axle
position.

16
ENGINE

17
Sr. No
Description
Specification
1
Number of Cylinder
3
2
Bore
88.9
3
Stroke
110
4
Displacement
2048
5
Compression Ratio
19.8:1
6
Compression Pressure
35-38
7
Firing Order
1-3-2
8
Rated Power
36 HP @ 2600 RPM
9
Maximum Torque
118 NM @1700 RPM
10
Rated Speed
2600 RPM
11
High Idle
2850 ± 50 RPM
12
Low Idle
850 ± 50 RPM
13
Injection Nozzle opening Pressure
250 ± 8 bar
Manifold, Cylinder Head & Inlet Valve Specifications
14
Numbers of Valve Per Cylinder
1
15
Stem diameter (mm)
Ø8.695 / Ø8.707
16
Head diameter (mm)
Ø38.25 / Ø38.50
17
Clearance in guide (mm)
0.051 / 0.025
18
Valve Seat angle (mm)
45º –20’ / +0’
19
Tappet Clearance (mm)
Inlet (Cold / Hot) - 0.4 / 0.3
Exhaust Valves
20
Numbers of Valve Per Cylinder
1
21
Stem diameter (mm)
Ø8.675 / Ø8.687
22
Port Diameter
26.06
23
Head diameter (mm)
Ø35.80 / Ø36
24
Clearance in guide (mm)
0.076 / 0.051
25
Valve Seat angle (mm)
45º –20’ / +0’
26
Tappet Clearance (mm)
Exhaust (Cold / Hot) - 0.5 / 0.4
ENGINE SPECIFICATIONS

18
Sr. No
Description
Specification
Valve Guide
27
Length - inlet (mm)
59.94
28
Length - exhaust (mm)
59.94
29
Inside diameter (mm)
8.763 / 8.738
Valve Springs
31
Initial length (mm)
42
32
Initial load (N)
250.0 N ± 10%
33
Final length (mm)
32.6
34
Final load
439.0 ± 10%
35
Free length (mm)
54.40 approx.
36
Spring rate ( at 30-70% of final load) N/mm
20.1 ± 0.8
Valve Tappets
37
Diameter (mm)
14.224 / 13.97
38
Running clearance (mm)
0.013 / 0.076
Valve Push Rods
39
Diameter (mm)
7.94 Thick solid Push rod
40
Length (mm)
248.3
Valve Timing
41
Inlet opens 7
7.94 Thick solid Push rod
42
Inlet closes
35º ABDC ± 2º
43
Exhaust opens
46º BBDC / 42º BBDC
44
Exhaust closes
10º ATDC ± 2º
Connecting Rod, Pistons & Cylinder Sleeves
45
Material
S48C
46
Bearing (big end) type
Replaceable Steel Backed Bimetal
ENGINE SPECIFICATIONS