Mahindra YUVRAJ 215 User manual

We are pleased to present the Service Manual for the “YUVRAJ 215” Tractor.
This Service Manual contains repair and maintenance information on Engine, Transmission,
Hydraulics and Other Aggregate of Tractor.
We hope this Service Manual will serve useful to you. For any further help or query contact
at the below mentioned address.
Foreword
Product Support
Customer Care Department
Mahindra & Mahindra Ltd.,
Farm Equipment Sector,
AkurliRoad,
Kandivli(E)
Mumbai - 400 101
PART NO: YUVR 215 SM01

Index
Description-------------------------------------------------------------- Page No
General Specifications ----------------------------------------------------------------- 05
Engine --------------------------------------------------------------------------------------- 07
Transmission ------------------------------------------------------------------------------ 29
Hydraulics ---------------------------------------------------------------------------------- 45
Front Axle & Steering------------------------------------------------------------------- 71

5
General Specifications
Engine
Type FMW100 Water Cooled Direct Injection
NA type Engine
No. of Cylinders 1
Bore / Stroke mm 100 / 110
Displacement cc 863.5
Rated Governed Speed 2300 ± 50
Low Idle R.P.M. 1050 ± 100
High Idle R.P.M. 2550 ± 50
Valve Clearance Cold - Inlet - 0.1, Exhaust- 0.1, Hot - Inlet - 0.1,
Exhaust - 0.1
Air Cleaner Wire Mesh & Foam type Oil Bath
Nozzle Opening Pressure 247 to 261 kg/sqcm (250 + 8 bar)
Cooling System Water cooled pressurised, Cap Operating
Pressure 0.9 kg/sqcm, without thermostat
Clutch
Clutch Type 200 mm dry Single plate Crerametalic type
Transmission
Type Sliding Mesh
No of Gears 6 Forward & 3 Reverse with Hi-low-Reverse
Selector Lever
Power Take Off Rear mounted six splines, constant running - 450
R.P.M
Standard PTO rpm at rated engine speed 605
Brakes Totally enclosed self energising dry disc with
heavy duty friction linings
Hydraulic
Type Hytech Hydraulics. Fully live Hydraulic with
Position & Draft Controls
Lifting Capacity (Kgs) 450
Tractor
Steering Type Worm & Roller
Tyre Size Front 5.2 x 14 - 8pr

6
Tyre Size Rear 8 x 18 - 4pr
Operating Weight & Distribution (Kgs)
Front 340
Rear 510
Total 850
Capacities (liters)
Engine (including filter) 2.5 (1.5 ltr in Oil Pan & 1ltr in Crank Case)
Cooling System (Approx) 3.8
Steering Gear Box 0.33
Fuel Tank 25
Transmission & Hydraulic System 15
Air Cleaner 0.5
Dimensions (In mm)
Overall Height (mm) 1690
Overall Length (mm) 2440
Ground Clearance (mm) 260
Overall Width (mm) 1175
Wheel Base (mm) 1480
General Specifications
Overall Height
Ground
Clearance
Overall Length
Wheel Base
Overall Width
***ComplyingtoBharat (Term) StageIII Emissionnorms
(All dimensions and specifications for guidance only & are subject to change without prior notice)

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ENGINE
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9
Engine Specifications
Engine
Type FMW100 Water Cooled Direct Injection
NA type Engine
No. of Cylinders 1
Bore / Stroke mm 100 / 110
Displacement cc 863.5
Rated Governed Speed 2300 + 50
Low Idle R.P.M. 1050 + 100
High Idle R.P.M. 2550 + 50
Valve Clearance Cold - Inlet - 0.1, Exhaust- 0.1, Hot - Inlet - 0.1,
Exhaust - 0.1
Air Cleaner Wire Mesh & Foam type Oil Bath
Nozzle Injection Pressure 247 to 261 kg/sqcm (250 + 8 bar)
Cooling System Water cooled pressurised, Cap Operating
Pressure 0.9 kg/sqcm, without thermostat
MANIFOLD, CYLINDER HEAD & VALVES
Inlet Valve
No of Inlet Valve 1
Stem Diameter (mm) 8.93 / 8.95
Port diameter (mm) 40 x 47
Clearance in guide,mm 0.05 to 0.08mm
Exhaust Valve
No of Exhaust Valve 1
Stem Diameter (mm) 8.93 / 8.95
Port diameter (mm) 32 x 38
Clearance in guide,mm 0.05 to 0.08mm
Tappet clearance Hot (mm) 0.1
Tappet clearance Cold (mm) 0.1
Valve Guides
No of Guides 2
Length Inlet & Exhaust (mm) 56
Inside diameter (mm) 9
Set Height of guide measured from 42 + 0.1
cylinder head Topdeck
Height Inlet & Exhaust (mm) 56

10
Valve Spring
Free length (mm) 49.5+/-0.5
Spring rate@30-70%of finest Load (N/mm) 23.88
Valve Tappets (Cam Follower)
Diameter (mm) 12
Running Clearance (mm) 0.016 to 0.045
Valve Push Rods
No of Push Rods 2
Diameter (mm) 10
Length (mm) 289.5+/-0.50
Valve Timing
Inlet opens (deg. BTDC) 9 ± 3
Inlet closes (deg. ABDC) 48 ± 3
Exhaust opens (deg. BBDC) 52 ± 3
Exhaust closes (deg. ATDC) 25 ± 3
CONNECTING RODS, PISTONS AND CYLINDER SLEEVES
Connecting Rod
Material EN18 D
Connecting Rod Big End Bearing
Material Steel back,'p' copper lead.
Connecting Rod Small End Bearing
Type Bush
Material Steel back, 'Y' copper lead.
Small end bush diameter (mm) 30 +0.02/+0.033
Pistion Rings
Number of Rings per Piston 3
Top Ring Material Half Key stone, crome plated
Middle Ring Material Bevelled
Bottom Ring Material (Oil Ring) Chromepelated conformable Oil ring.
Ring Width (Axial)
Top (mm) 2.563
Middle (mm) 2
Bottom (mm) 3
Engine Specifications

11
Ring Gap
Top (mm) 0.25 to 0.45
Middle (mm) 0.60 to 0.85
Bottom (mm) 0.35 to 0.55
Piston
Type Re-entrant
Material Aluminium
Dia at crown 99.35 +/-0.015
Dia at skirt 99.88
Bumping Clearance 1.12 to 1.2
Number of Ring Groove (No.) 3
Ring Groove Width (mm)
Top Groove (mm) 2.7
Middle Groove (mm) 2
Bottom Groove (mm) 3
Ring Groove Clearance
Top groove (mm) 0.137
Middle groove (mm) 0.08/0.04
Bottom groove (mm) 0.09/0.07
Piston Pin
Inner Diameter (mm) 16
Outer Diameter (mm) 30
Clearance in piston (mm) 0.016/0.004
Clearance in con rod (mm) 0.434/0.268
Length (mm) 78
Cylinder Sleeve
Type Non Replaceable wet liner
Material Synthetic Low alloy gray cast iron
Wall thickness (mm) 8.5
Sleeve I.D. (mm) 100
Max. taper (mm) 0.015
Max. ovality (mm) 0.01
Sleave I.D. Discard limit (mm) 100.030 + 0.150
Engine Specifications

12
LUBRICATION SYSTEM
Pressure Requlating Valve Between the oil pump and oil filter
Location Oil pump body In front lower side of crankcase
Spring free length (mm) 15
Opening pressure (kg/cm2) 3
By-Pass Valve
Location Filter Head "Extreme left on the Outer wall“ of crank case
when viewed from Front of Engine"
Opening pressure (kg/cm2) 0.8 to 1 bar
OIL PUMP INTERNAL ROTOR CAMSHAFT DRIVERS
Backlash (mm) 0.05 to 0.08
Drive pinion to camshaft (mm) 0.08
Clearances
Gears to housing (mm) 0.075 - 0.153
Drive shaft to body (mm) 0.037 to 0.074
Drive pinion to body ( end float ) (mm) 0.075 to 0.123
COOLING SYSTEM
Type Water cool, force feed
Water Pump Type Centrifugal
TIMING GEAR TRAIN, FRONT COVER AND CAMSHAFT
Camshaft
Material EN -8
Number of bearings (No.) 2
Bearing Diameter Front (mm) 35
Bearing Diameter Rear (mm) 25
Running clearance (mm) 0.39 / 0.93
Exhaust cam lift (mm) 9
Inlet cam lift (mm) 8.9
Max cam shaft lobe 30
Timing Gears
Number of teeth 40
Crankshaft gear (No.) 1
Camshaft gear (No.) 1
Backlash between any pair of gear (mm) 0.08
Engine Specifications

13
CRANKSHAFT
Material Alloy steel EN 19 C
Main journal diameter (mm) 66
Running clearance main journal (mm) 0.028 / 0.153
Crank-pin diameter (mm) 53
End clearance (float) (mm) 0.2 to 0.5
Running clearance crank pin (mm) 0.052- 0.098
Rear end oil seal dia. (mm) 64
Main Bearings
Type Replaceable, shell
Material Steel backed babbit Bi- Metal
WEAR LIMITS
Cylinder sleeves
Bore diameter (mm) 100.030 + 0.150
Ovality (mm) 0.06
Taper (mm) 0.06
Piston Rings
Ring gap
First ring (mm) 1
Second ring (mm) 2
Third ring (mm) 2
Valve train
Valve guide clearance (mm) 0.05
Tappet valve clearance (mm) 0.3
Spring rate N/mm (Kg/mm) 16 (1.63)
Crankshaft
Main bearing clearance (mm) 0.18
End play (mm) 0.8
Connecting rod
Big end bearing clearance (mm) 0.15
End play (mm) 0.8
Engine Specifications

14
Engine Torque Values
TORQUE CHART FOR YUVRAJ 215 - FMW100 ENGINE
SR. DESCRIPTION & BOLT/NUT/STUD USED TORQUE-Nm
NO.
CRANKCASE SUB-ASSEMBLY
1 Fip.Mtg Stud to crank case(M8 x 22) 15 to 20 Nm
2 Main brg housing mtg stud to crank case- ( M10 x 20) 25 to 30 Nm
3 Camfollwer bkt Allen bolt (M10 x 48.5 - 12.9) 55 to 60Nm
4 Stud for Cyhead at rocker side 45 to 50 Nm
5 Stud for Cyhead at injector side 46 to 50 Nm
6 Engine flange mtg bolt (M 12 x 30) 65 to 70 Nm
7 Oil sump mtg bolt (M8 x16 - 8.8) 20 to 25 Nm
8 Counter Unbalance shaft 40 to 50 Nm
9 Oil pump mtg bolt (Hex bolt - M8 x 35 – 8.8) 25 to 30Nm
10 Hex Bolt M8 X 20 For oil pump gear and water pump
rear mounting bolts 20 to 25Nm
11 Oil Pump spacer Nylock nut 25 to 30Nm
12 Allen screw for Oil filter mtg bkt (M8 x 30 - 10.9) 25 to 30Nm
13 Hex bolt for low idle setting (M6 x 55 x 55 - 8.8) 10 to 12Nm
13 Hex bolt for Pull to stop lever bkt (M6 x 12-8.8) 10 to 12 Nm
14 Hex Socket Pipe Plug (M10X1) 15 to 18 Nm
15 Relief Valve Assembly 25 to 30 Nm
CRANKSHAFT, FLYWHEEL SUB-ASSEMBLY
16 Main brg housing Hex Nut ( M10 - 8) 45 to 55 Nm
17 Allen screw for flywheel (M12 x 75 - 12.9) 100 to 120 Nm
18 Allen screw for Balance weight (M10 x 50-10.9) 65 to 70 Nm

15
CAM SHAFT,PUSH ROD,TIMING COVER SUB-ASSEMBLY
19 High Idle seting Hex Nut (M8 - 8) 18 to 22 Nm
20 Hex bolt for Timing cover (M 8 x 30 - 8.8) 25 to 30Nm
21 Hex bolt for P.T.O. shaft (M 10 x 45 - 8.8) 48 to 52 Nm
PISTON,CON. ROD SUB -ASSEMBLY
22 Con Rod bolt (M10 x 48 - 12.9) 60 TO 65 Nm
23 Stud for water inlet flange (M8 x 22 ) 12 to 15 Nm.
24 Hex bolt for closed flang of water inlet (M8 x 12-8.8) 20 to 25 Nm
CYLINDER HEAD SUB-ASSEMBLY
25 Injector flange stud (M 8 x 40 - 5.6) 10 to 12 Nm
26 Exh. And Air Intake manifold mtg. stud (M10X42X1.5) 45 to 50 Nm
27 Exh.manifold mtg bolt (M 8 x 25) 20 to 25 Nm
28 Breather pipe mtg stud (M 6 x 30 - 5.8) 10 to 12 Nm
29 Hex nut for Adjustment screw of rocker (M8) 18 to 22Nm
30 Hex bolt for Rocker shaft locking (M6 x 16-8.80 10 to 12 Nm
31 Hex Nut for cy.head (M12) 127 to 147 Nm
32 Rocker cover hex bolt (M8 x 50-8.8) 25 to 30 Nm
33 Rocker cover hex bolt (M8 x 75-8.8) 25 to 30 Nm
34 Hex nut for breather pipe (M 6 – 8.8) 10 to 12 Nm
35 Water Temperature Sensor 25 to30 Nm
36 Oil Pressure Switch 15 to 20 Nm
TORQUE CHART FOR YUVRAJ 215 - FMW100 ENGINE
SR. DESCRIPTION & BOLT/NUT/STUD USED TORQUE-Nm
NO.

16
TORQUE CHART FOR YUVRAJ 215 - FMW100 ENGINE
SR. DESCRIPTION & BOLT/NUT/STUD USED TORQUE-Nm
NO.
INJECTION EQUIPMENT SUB- ASSEMBLY
37 Hex Nut for FIP (M8 - 8) 18 to 22 Nm
38 Hex bolt for H.P.pipe clamp mtg (M8x16-8.8) 25 to 30 Nm
39 Injector flange Hex Nut (M8 - 8) 25 to 30 Nm
40 Fuel filter bkt Mrg bolt (M10 x 30 - 8.8) 45 to 50Nm
41 Hex Nut for fuel filter mtg bolt (M10 - 8) 45 to 50 Nm
42 Fuel filter mtg bolt (M10 x 30 - 8.8) 45 to 50 Nm
43 Banjo Bolt M14 for fuel filter 20 to 25 Nm
44 M6 Banjo bolt for injector overflow pipe 5 to 7 Nm
AIR FILTER, EXHAUST SILENCER SUB-ASSEMBLY
45 Exh. Manifold manifold hex nut (M10) 45 to 50 Nm
46 Hex bolt for stub pipe mtg (M8 x 30-8.8) 25 to 30 Nm
47 Hex nut for stub mtg bolt (M8 – 8.8) 25 to 30 Nm
48 Hex nut for silencer clamp (M8 – 8.8) 25 to 30 Nm
49 Air cleaner manifold hex nut (M10 – 8.8) 45 to 50 Nm
STARTER MOTOR, ALTERNATOR SUB-ASSEMBLY
50 Hex bolt for starter mtg (M10 x 30 - 8.8) 45 to 50 Nm
51 Hex bolt for Alternator mtg bkt (M8 x 20 - 8.8) 25 to 30 Nm
52 Hex bolt for Alternator mtg (M8 x 110 - 8.8) 25 to 30 Nm
53 Hex bolt for Radial bkt (M 8 x 25 - 8.8) 25 to 30 Nm
54 Nut for Alternator Adj bolt (M8) 25 to 30 Nm

17
TORQUE CHART FOR YUVRAJ 215 - FMW100 ENGINE
SR. DESCRIPTION & BOLT/NUT/STUD USED TORQUE-Nm
NO.
COOLING SYSTEM SUB-ASSEMBLY
55 Hex bolt for water pumpmtg. Bkt.(Rear) (M8X20X8.8) 25 to 30 Nm
56 Hex bolt for water pulley and spacer (IM6X35X-8.8) 10 to 12 Nm
57 Hex bolt for Cooling fan and Spacer (M8 x 20-8.8) 25 to 30 Nm
58 Hex nut for Flange for Inlet Hose (M8 - 8) 12 to 15 Nm.
59 Hex bolt for Fan spacer (M6X30) 10 to 12 Nm
60 Hex bolt for Flange for Outlet Hose (M8 x 20-8.8) 12 to 15 Nm.
ACCESSORIES SUB-ASSEMBLY
62 Hyd pump mtg bkt Flange Headed Bolt(M12 x 75 - 12.9) 45 to 50 Nm
63 Hex bolt for hour meter adapter (M6X16X8.8) 10 to 12 Nm
64 Hex bolt for hour meter (M8 x 16 - 8.8) 25 to 30 Nm
65 Plug Magnetic Drain ( Oil Pan Drain Plug ) 40 to 50 Nm
66 Oil Filter 15 to 20 Nm
67 Fuel Injection Pump M12 Banjo bolt 20 to 25 N.m
68 Fuel Injection Pump M8 banjo bolt and fuel return
line M8 banjo bolt 6 to 10 N.m
69 Tappet Bolt for Crankshaft Pulley 45 to 50 Nm
70 HPP Nut M12 at FIP and M14 at Injector End 20 to 25 N.m

18
Removal of Engine :
Dismantling of Bonnet & Radiator –
1 Remove the two nos. nuts of bonnet of LH
& RH side.
2 Remove the two nos bolts of bonnet. &
remove the Bonnet.
3 Drain the coolant in the radiator by
removing the radiator drain plug.
4 Remove the brace plate of radiator
5 Remove the clip of radiator each inlet &
outlet hose.
6 Remove the two nos. radiator mounting
spring loaded bolts & plain washer and
remove the radiator.
7 Remove the four nos bolts (spanner size
12 mm) of fan blade & remove the fan
blade.
Nut
Bolt
Brace
Plate
Hose
Pipe
Hose
Clip
Radiator
Mounting
Bolt
Fan
Fan Bolt
Bonnet
Engine

19
8 Remove the air cleaner by removing the
two nos bolts of air cleaner assembly.
9 Remove the two Allen bolts each of suction
pipe & pressure pipe. (3/16 size bolt of
Pressure pipe & 7/32 of suction pipe).
10 Remove the hydraulic filter in suction line
by removing two bolts of it.
11 Remove the suction pipe. (Suction pipe
below the transmission housing has to be
removed by removing two bolts with the
help of 7mm ratchet.)
12 Remove the four nos of hydraulic pump
mtg. bolts (spanner size- 12/13) & remove
the hydraulic pump.
13) Remove the two Allen bolts of hyd. Pump
bracket(10mm) and remove the hydraulic
bracket.
Air
Cleaner
Mounting
Bolt
Hydraulic
Pump
Allen Bolt
for Suction
Pipe
Hydraulic
Filter
Mounitng
Bolts
Mounting
Bolt
Suction
Pipe
Hydraulic
Pump
Mounting
Bolt
Mounting
Allen Bolt
Hydraulic Pump
Mounting Bracket
Engine

20
14 Remove the four nos bolts (13mm size)
stub pipe on exhaust manifold & remove
the stub pipe with silencer assembly.
15 Remove the steering wheel with the help
of steering puller
.
16 Remove the eight nos of Phillips screws of
scuttle top panel by the screwdriver &
remove it.
17 Remove the four nos of Phillips screws of
scuttle front panel by the screwdriver &
remove it.
18 Disconnect all wiring harness couplers
connected to the scuttle.
19 Remove the pull to stop knob.
20 Remove the three screws of scuttle LH side
panel & remove the bonnet mtg. bracket.
21 Remove the three screws of scuttle RH side
panel.
Mounting
Bolt
Stub Pipe
Steering
Wheel
Steering Wheel
Puller
Phillips
Screw
Scuttle
Scuttle Pannel
Front
Scuttle
Pannel LH
Scuttle
Pannel RH
Engine