Mahindra 35 Series Service Manual Download Page 125

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35 Series 4WD, Model - 3535, 4035, 4535 and 5035 SM June’08

CHAPTER - 7

Summary of Contents for 35 Series

Page 1: ...Click here to go on INDEX SERVICE MANUAL 3535 4035 4535 5035 GEAR 35 Series 4WD Main Page...

Page 2: ...C47 C54 Crankcase Crankshaft Main Bearings Flywheel C55 C68 Special Notes Trouble Shooting C69 C76 Cooling System C77 C86 Air Cleaner C87 C92 Fuel System C93 C111 GROUP C ENGINE GROUP B SPLITTING THE...

Page 3: ...H STEERING Steering H1 H19 GROUP F FRONT AXLE Front Axle F1 F25 GROUP J CHARTS Engine Differential Assembly Rear Axle Rear Axle Carrier and Brake Assembly Front Axle Differential Front Axle Side Sect...

Page 4: ...y messages Why is SAFETY important to you ACCIDENTS DISABLE AND KILL ACCIDENTS ARE COSTLY ACCIDENTS CAN BE AVOIDED Work Safely Follow these Rules 1 Always wear safety glasses when using a hammer chise...

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Page 6: ...35 Series 4WD Model 3535 4035 4535 and 5035 SM June 08 Group A G e n e r a l General A1 A21...

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Page 8: ...the safety messages Why is SAFETY important to you ACCIDENTS DISABLE AND KILL ACCIDENTS ARE COSTLY ACCIDENTS CAN BE AVOIDED Work Safely Follow these Rules 1 Always wear safety glasses when using a ham...

Page 9: ...he relevant section of the group B 1 Bearings Inspect for evidence of overheating cracks scores pitting and general wear Replace if necessary Soak in oil wrap and cover with grease proof paper until r...

Page 10: ...ale for tightening bolts with quality specification 8G Diameter of bolt Coarse thread NC Inch mm lb ft kg m 1 4 6 35 008 0 to 009 4 01 1 01 3 5 16 7 94 015 9 to 018 1 02 2 02 5 3 8 9 52 027 5 to 030 4...

Page 11: ...your skin and cloths If contaminated wash it in water immediately Before recharging the battery remove it from the machine Before recharging remove cell caps FUSE Use fuses with Specified capacity Nev...

Page 12: ...ce of any trouble that might develop and take corrective measures in quick time Every dealer who sells tractors has the obligation of having well trained servicemen to take care of the machines in ope...

Page 13: ...tion is a thorough preventive maintenance measure It calls for a well trained serviceman with a detailed knowledge of the tractor and the functioning of the various units Off season inspection is the...

Page 14: ...Before reassembly carefully inspect all parts to see whether they can be re used Replace if necessary Ball bearings must be thoroughly cleaned and well dried before inspection To determine the degree...

Page 15: ...reassembling external snaprings or internal snaprings they must be positioned so that sharp edge faces against the direction from which force is applied See fig When inserting spring pins their splits...

Page 16: ...ild up in the running components which could lead to immediate or low hours of use failures Engine Run in Schedule NOTE Do not run the engine at low or high idle speeds for long period after installin...

Page 17: ...steering wheel play General After Turning the switch Key 1 Check the Headlights taillights and hazard lights clean it necessary 2 Check the performance the meters and gauges After Starting the engine...

Page 18: ...the distance between these two points and this distance must be the same as measured before without variance To adjust the TOE IN shorten or extend the tie rod clockwise or anti clockwise When the TOE...

Page 19: ...ovided at backside of FIP insert dial ASN0600G013 with adapter as shown in Fig 1 5 Rotate crankshaft pulley in clockwise direction as seen from flywheel side till the pointer matches with crankshaft p...

Page 20: ...98 inch 20 to 25 mm 1 Loosen jam nut B 2 Turn the turn buckle C anticlockwise from eyesight view to decrease play and clockwise to increase play A SOP for adjusting Brake Pedal Free Play Measure free...

Page 21: ...After all coolant is drained install the hose securely 4 Fill with clean water and cooling system cleaner solution 5 Follow direction of the cleaner instruction 6 After flushing fill with clean water...

Page 22: ...he cooling water level drops add only clear water In case of leakage add anti freeze and water is the specified mixing ratio Anti freeze absorbs moisture keep unsealed anti freeze in the lightly seale...

Page 23: ...coming from pipe C Retighten the drain plug by hand Servicing the fuel filter 1 It is recommended to replace the fuel filter every 500 hrs 2 To remove Filter unscrew the filter D from adaptor E 3 Chec...

Page 24: ...ays Periodically Change Fuel Filter earlier if required Spinon Element Every 200 Hrs COOLING SYSTEM Check Coolant Level in Radiator top up if necessary Every 50 Hrs Check Radiator Hose Connections tig...

Page 25: ...35 Series 4WD Model 3535 4035 4535 and 5035 SM June 08 Group B Splitting the Tractor Splitting the Tractor B1 B32...

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Page 27: ...embly Apply Tractor parking brakes and place wedges to hold the rear wheels Drain the water from the Radiator from two places a Engine Block side drain plug b Radiator bottom tank drain plug 2 Open th...

Page 28: ...gas spring from hood and then remove hood from hinge assembly 5 Remove side panels from locating points 6 Disconnect horn 7 Loosen the Air cleaner inlet hose connections from the intake manifold and...

Page 29: ...radiator mounting bolts and remove the radiator 11 Remove the front bottom grill and bonnet locking bracket 12 Disconnect the LH RH hoses to the power steering cylinder and plug the hoses to prevent...

Page 30: ...heck for steering noise and vibrations Splitting Between Front Axle Engine 22 Remove the bolts connecting the Front Axle Semi chassis in pillow block 23 Move the semi chassis away from the front axle...

Page 31: ...the mud splash guards 6 Disconnect the following hydraulic oil connections Plug the pipes to prevent oil spillage a Hydraulic pipe from filter to Hydraulic pump b Hose from Hydraulic pump to HSU c Ho...

Page 32: ...ut and use steering wheel puller to remove the steering wheel 15 Dismantle the steering column cover disconnect the wiring harness to PTO engaging switch 16 Dismantle the scuttle cover 17 Disconnect t...

Page 33: ...bolts can result in serious damage to both Engine and clutch housing Clutch housing needs to be held in place with external support Check the freeplay of clutch and brake pedals NOTE First align the...

Page 34: ...and jack 3 Remove the rear LH RH wheels 4 Disconnect the LH RH fender wiring harness to P T lamp plow lamp remove the wiring harness from fender clamps 5 Dismantle the ROPS Fender connecting bracket 6...

Page 35: ...rom mounting brackets 14 Disconnect wiring harness of fuel level sensing float 15 Disconnect the pipe from suction manifold to hydraulic filter Filter to oil pump plug the pipes 16 Dismantle the oil f...

Page 36: ...le Assembly Removing of Control Levers Knob 19 Remove the PC DC Range Speed lever knobs slow fast valve knob 20 Remove the differential lock foot pedal 21 Remove the isolator mounting bolts from Rear...

Page 37: ...trolley jack 25 Remove the bolts which are connecting the transmission housing and Rear Axle 27 Move the rear axles away from the transmission case REJOINING THE TRANSMISSION AND REAR AXLE 1 Follow th...

Page 38: ...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...

Page 39: ...old Down ROPS Rollbar A 1 Remove quick lock pins B and headed pins C 2 Loosen the knob D 3 Turn the rollbar A of ROPS till it stops 4 Reinstall pins C and B into its position on ROPS To Raise ROPS in...

Page 40: ...ng brakes and place wedges to hold the rear wheels 2 Remove wiring connections of P TS lamps mounted on ROPS 3 Loosen bolts A from ROPS fender connecting brackets 4 Support the ROPS rollbar to avoid a...

Page 41: ...om hood clamps 4 Loosen the nut B of gas spring C remove gas spring The hood needs to be held in place with external support 5 Remove the 4 nuts D of hood bracket gently take out hood 6 Hold the hood...

Page 42: ...able from its negative terminal then remove battery cable from positive terminal 4 Disconnect fender wiring harness remove from fender clamps 5 Loosen the fender mounting bolts A 6 Hold the fender B f...

Page 43: ...el 3535 4035 4535 and 5035 SM June 08 Removal Refitment of Seat Removal Refitment of Seat 1 Loosen the seat mounting nuts A from the bracket B 2 Remove the seat 3 Refit the removed parts in the revers...

Page 44: ...2 Remove rear wheel of LH side A to access the fuel tank B NOTE In case of 29 33 38 PTO HP tractor LH side fender required to be removed to access fuel tank For 43 PTO HP tractor No need to remove LH...

Page 45: ...d 2 Remove the battery cable from its negative terminal and then positive terminal 3 Remove the wing nut A of the Battery holding bracket stay rods B and remove the bracket C 4 Remove the battery Refi...

Page 46: ...rst remove the battery cable from its negative terminal then remove battery cable from positive terminal 4 Disconnect the cables connected to the Starter motor 5 Dismantle the Starter Motor mounting b...

Page 47: ...ght hand withdraw mounting bolt towards rear of engine 8 Assemble the removed parts in the reverse sequence of removal NOTE Alternator maintenance Repair should be done by Authorized Dealer Distributo...

Page 48: ...thumb midway between the pulleys 2 The belt slack should be approximately If the belt tension is found to be incorrect then adjust the belt tension as below a Loosen the Alternator mounting bolt and...

Page 49: ...cles are thrown away rapidly from the body tube After passing from hopper slot they fall in the dust collector The precleaned air then passes through paper filter element before entering the engine A...

Page 50: ...d 7 Check the dust unloader valve E and clean if necessary 8 Turn the clamp F of air cleaner G 9 And remove cover H 10 Remove Primary Element I Remove Secondary Element Inner Element ONLY if it is to...

Page 51: ...n is not dented Vibration would quickly wear a hole in filter c Be sure rubber sealing surfaces are in good condition on both ends If damaged replace element d Before you install Primary Element clean...

Page 52: ...s 3 Open the steering wheel cap C Remove the Steering Wheel Nut D and take out the Steering wheel E with the help of puller 4 Loosen the steering column cover bolts F 5 Disconnect the wiring harness t...

Page 53: ...ast Valve Knobs 10 Remove the differential lock foot pedal 11 Dismantle the instrument cluster Steering wheel scuttle steering column covers 12 Disconnect the front rear wiring harness from the centra...

Page 54: ...Refitment of the Hydraulic Pump Always use new O Rings Using damaged or used O Rings will lead to leakage 1 Place new O Rings on pump flange Install pump on engine 2 Install cap screws for connecting...

Page 55: ...m Place a tray under filter to collect the oil Remove this filter by using adjustable belts strap Hydraulic and Transmission Strainer Clean suction strainer during every oil change The suction straine...

Page 56: ...remove the switch NOTE After removal of the switch preserve the shims Refitment of Neutral Safety Switch 1 Position forward reverse lever in neutral position 2 Refit the switch by using removed shims...

Page 57: ...ylinder Head Valves C19 C30 Connecting Rods Pistons Cylinder Sleeves C31 C40 Lubrication Systems C41 C46 Timing Gear Train Front Cover Camshaft C47 C54 Crankcase Crankshaft Main Bearings Flywheel C55...

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Page 59: ...35 Series 4WD Model 3535 4035 4535 and 5035 SM June 08 CHAPTER 1 INTRODUCTION...

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Page 61: ...Parts Description 5035 4535 4035 3535 MANIFOLDS CYLINDER HEAD VALVES INLET VALVES Number of per cylinder 1 Stem diameter mm 8 695 8 707 Head diameter mm 38 25 38 50 Clearance in guide mm 0 051 0 025...

Page 62: ...Small end bush dia mm 30 950 30 975 PISTON RINGS Number of rings per piston 3 Type Cam Ground Oval Top Keystone CKS Plated Middle Taper faced Bottom Chromium Plated Conformable Oil Ring Width Axial m...

Page 63: ...are Max taper mm 0 013 Max ovality mm 0 013 Sleeve I D Discard limit mm 88 976 and above LUBRICATION SYSTEM PRESSURE REGULATING VALVE Location On oil pump Spring free length mm 63 5 0 010 Spring Initi...

Page 64: ...Centre 46 025 45 999 Rear 38 1 37 846 Running clearance mm 0 089 0 038 Exhaust cam lift 6 325 Inlet cam lift 6 274 TIMING GEARS Number of teeth Crankshaft gear 33 Cam shaft gear 66 Injection pump gear...

Page 65: ...9 05mm 18 to 22 Fitment Of Front Cover Front cover To Crankcase Mounting Bolt G 7 938x50 8 mm Hx Hd 18 to 22 Front Cover To Crankcase Mounting Bolt G7 938x63 5 Hx Hd v 18 to 22 Alternator Mounting Bra...

Page 66: ...cker Arm Mounting Stud 12 to 14 Cylinder Head To Crankcase Mounting Bolt 7 16 UNC Short 60 to 65 Rocker Arm Mounting On Cylinder head Bolt 7 16 UNC Long 60 to 65 Rocker Arm Mounting Nut M10 x 1 5 25 t...

Page 67: ...rwise oil leakage will result 10 Crankshaft rear bearing takes end thrust 11 Flywheel ring gear replaceable 12 Floating screen for oil pump before installing thoroughly wash in gasoline 13 Crankshaft...

Page 68: ...es These engines have superior specific fuel consumption and meet US Tier IV 50 Hp emission norms B CONSTRUCTION i Cylinder Block The block is reinforced with ribs so it easily acts as part of the fra...

Page 69: ...C 13 35 Series 4WD Model 3535 4035 4535 and 5035 SM June 08 Introduction LUBRICATION CIRCUIT DIAGRAM For External Check...

Page 70: ...peed from idling to full load For complete detailed servicing information on diesel fuel system components refer to the fuel injection system service manual iv Pistons The Aluminium Alloy Pistons are...

Page 71: ...and securely block the rear wheels 11 Disconnect the drag link If power steering is fitted disconnect the power steering oil pipes two at starter side 12 Support the front of the tractor to take most...

Page 72: ...ck support of engine below oil sump Place mini jacks between front axle front axle support lock to avoid swinging of engine Place transmission jack below transmission case rectangular part Raise the j...

Page 73: ...e 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 f...

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Page 75: ...35 Series 4WD Model 3535 4035 4535 and 5035 SM June 08 CHAPTER 2 MANIFOLDS CYLINDER HEAD VALVES...

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Page 77: ...are operated by rocker arms shaft mounted on the cylinder head Lubrication for the valve operating mechanism is provided through rifle drilled passages in the crankcase and cylinder head The valve ro...

Page 78: ...c Remove the two nut 1 3 from studs 4 3 from the outer valve lever shaft bracket Which hold the valve lever shaft brackets cylinder head d Remove the bolt 2 3 from the centre long valve lever bracket...

Page 79: ...ocker arm spring rocker arm bracket rocker arm to the shaft and secure them with a washer and retaining ring 3e INSTALLATION a Loosen the lock nuts on each valve lever and back off the adjusting screw...

Page 80: ...in para 3a 3 Remove the push rods and identify them so they can be installed in their original positions 4 Remove the thermostat housing by pass hose 5 Remove the three bolts then remove the thermosta...

Page 81: ...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 sligh...

Page 82: ...Washer 4 Plate 5 Key 6 Camshaft 7 Tappet 8 Rod 9 Rocker 10 Circlip 11 Washer 12 Screw 13 Nut 14 Arm rocker 15 Arm rocker 16 Bush 17 Bracket 18 Nut 19 Washer 20 Shaft 21 Plug 22 Spring 23 Spacer 24 Br...

Page 83: ...cylinder head and out of exhaust valve ports Flush out the water jacket to remove scale and dirt NOTE Make sure water passages are free of obstructions rust or scale Inspect the cylinder head and the...

Page 84: ...ould be removed by fine grinding the tips and removing sufficient metal so as to give flat smooth finish However either valves or the rocker arms which have deep indentations should not be salvaged 4f...

Page 85: ...vice of cylinder head 1 During cylinder head overhaul Nozzle protrusion protrusion of nozzle tip from head bottom face should be checked thoroughly as it affects the fuel spray pattern of the nozzle 2...

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Page 87: ...35 Series 4WD Model 3535 4035 4535 and 5035 SM June 08 CHAPTER 3 CONNECTING RODS PISTONS CYLINDER SLEEVES...

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Page 89: ...f the sleeve 6 Replace inserts 9 2 in bearing caps 8 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 cy...

Page 90: ...fit of the piston pin f Check the piston pin for wear or corrosion g If the piston pin is a slack fit in an otherwise serviceable piston the piston bore and connecting rod bushing can be reamed to tak...

Page 91: ...n starting the bottom ring and working up NOTE Multi piece oil control rings should be fitted to the top oil control groove The expander 1 8 must be installed first followed by the two flat rings 2 8...

Page 92: ...r the remaining piston assemblies NOTE When correctly positioned the connecting rod cap bearing half will stand out 0 7 mm 0 030 in above the cap surface and will engage inside the connecting rod half...

Page 93: ...Check cylinder sleeve wear before removal see fig 10 NOTE Removal on the cylinder sleeves need only be carried out if inspection proves this necessary a Remove the piston assemblies as detailed in pa...

Page 94: ...eeves for scoring or signs of corrosion 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 s...

Page 95: ...e cylinder sleeve 4 With dial indicator pointer set on the flange of the cylinder sleeve Adjust the indicator to zero Move the indicator block until the pointer drops to the crankcase deck and check t...

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Page 97: ...35 Series 4WD Model 3535 4035 4535 and 5035 SM June 08 CHAPTER 4 LUBRICATION SYSTEMS...

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Page 99: ...4 4 from the shaft c Remove bolts 4 3 which secure the cover 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 spr...

Page 100: ...stigauge This must not exceed the dimension given in specifications h All sealing rings and gaskets must discarded If the clearance is excessive check the end plate using a straight edge and feeler ga...

Page 101: ...e correct grade of lubricating oil to the oil level mark on the dipstick 8 LUBRICATING OIL FILTERS 1 REMOVAL a Unscrew the spin on oil filter from filter head and install new filter NOTE Engine Oil an...

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Page 103: ...35 Series 4WD Model 3535 4035 4535 and 5035 SM June 08 CHAPTER 5 TIMING GEAR TRAIN FRONT COVER CAMSHAFT...

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Page 105: ...of the crankshaft through a train of gears All gears are punch marked to ensure correct timing End float is controlled by thrust washer plate 4 3 The drive gear is key shrunk to the camshaft end B FR...

Page 106: ...nt 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 Raise engine until crankshaft pulley wi...

Page 107: ...ear b Camshaft end float c Cam lobe lift NOTE 2 Cam lobe lift may be checked by means of a dial indicator gauge Rest the stylus of the dial indicator on one of the push rods Rotate the engine one revo...

Page 108: ...mshaft bearing f Inspect the valve tappets for wear to specifications 4 ASSEMBLY a Install the thrust plate on the camshaft b Fit a new key to the camshaft then press on the camshaft gear to leave a c...

Page 109: ...e are supplied semi finished and must be line reamed to specified dimension after assembly a After reaming thoroughly blowout the casting and oil ways to ensure that there is no metal deposit left b E...

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Page 111: ...35 Series 4WD Model 3535 4035 4535 and 5035 SM June 08 CHAPTER 6 CRANKCASE CRANKSHAFT MAIN BEARINGS FLYWHEEL...

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Page 113: ...ng mechanisms in later models During manufacture main bearing caps are rough machined then assembled to the crankcase prior to being line reamed This results in each bearing cap being fitted for only...

Page 114: ...empt by welding remove the loose gear and replace with a new one or replace flywheel with ring gear 1 Remove the ring gear by heating with a torch or splitting with a chisel and driving off 2 Heat a n...

Page 115: ...the timing cover d Invert the engine e Remove oil pan and adapter plate f Remove the rear oil seal retainer by removing 7 cap screws 2 1 g Remove the bearing cap bolts 1 4 Then remove the bearing caps...

Page 116: ...ing from the journals to the bearings 1 Any bearings that do not show all over even blueing should be replaced by new It is advisable to replace all bearings by new ones if an original one is faulty 2...

Page 117: ...14 1 319 1 3215 1 324 1 3200 1 316 1 321 1 3235 1 326 1 3310 4 2 420 2 422 2 4240 2 420 2 4200 2 432 2 436 2 4360 2 438 2 4390 5 0 125 0 125 0 125 0 125 0 125 0 135 0 135 0 135 0 135 0 135 6 MUST BE C...

Page 118: ...f possible Ensure that the garter spring is fitted and in position Locate the retainer on the dowels Crankcase Crankshaft Main Bearings Flywheel 9 Fit the five retainer bolts and tighten to the correc...

Page 119: ...rods connecting rod bearings and bearing caps to the crankshaft with the identification numbers to the fuel injection pump side then tighten the bolts to the specified torque e Check the connecting r...

Page 120: ...ments The pump to be fitted Matching the mark Match the TDC mark on main drive pulley with the pointer on front cover Scenario I Engine is fitted on Tractor and Crankshaft is rotated while FIP is in r...

Page 121: ...PRE LOAD L Further fix the assembly of dial indicator with Special Tool on the FIP camshaft near a distributor with the help of Nut provided at the center ensuring that the needle rests on PLUNGER of...

Page 122: ...he component CHECKING COMPRESSION Use compression gauge to check compression in all cylinders of the engine individually It is advisable to check cylinder compression before overhauling Comparison of...

Page 123: ...ubrication functions properly and no bearing is starved Restart the engine and let it run at medium speed for approximately one hour If new cylinder sleeves and pistons were installed it is necessary...

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Page 125: ...35 Series 4WD Model 3535 4035 4535 and 5035 SM June 08 CHAPTER 7 SPECIAL NOTES TROUBLE SHOOTING...

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Page 127: ...ure NOP spray pattern and leakage Service or replace as necessary c Check engine compression while the injectors are removed If the compression is low on one or more cylinders make the necessary repai...

Page 128: ...e 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...

Page 129: ...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 Insu...

Page 130: ...ve 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 insp...

Page 131: ...y 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 F...

Page 132: ...ers 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 pu...

Page 133: ...35 Series 4WD Model 3535 4035 4535 and 5035 SM June 08 CHAPTER 8 COOLING SYSTEM...

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Page 135: ...n NOTE COOLING SYSTEM PROTECTION Operate the engine with light load and with the fuel rack at 3 4 position Anti Freeze Water 50 50 60 40 Freeze Protection 340F 640F Boil over protection 2650F 2750F wi...

Page 136: ...ater passages in the Cylinder Block absorbing the heat from the Cylinder Walls The Coolant then flows into the Cylinder Head Water Jacket and to the Nozzle Tip Area This flow within the Cylinder head...

Page 137: ...defective i e Rubber Seals and Valve Springs broken replace it 2 Removal a Drain the cooling system b Remove the vertical exhaust silencer precleaner and raise the hood c Disconnect the battery earth...

Page 138: ...ill with anti freeze solution The system should be kept filled with clean water with a rust inhibitor or anti freeze solution d Method of De Scaling and Flushing A Chemical Scale Remover is available...

Page 139: ...be worked over the fan blades d Remove the six round headed capscrews 6 4 and their washers and nuts which secure the fan housing to the radiator and move the housing back towards the pulley as far a...

Page 140: ...uds and towards the radiator 7 THERMOSTAT The Blocker type Thermostat is located in Thermostat Housing 2 7 The Thermostat controls the Engine operating temperature When the Engine is cold the Thermost...

Page 141: ...re hardness or conversely sponginess In first case hardness leads to lack of flexibility and cracking the latter causing leakage and also allows the passage of small particles of rubber into the Radia...

Page 142: ...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 Defecti...

Page 143: ...35 Series 4WD Model 3535 4035 4535 and 5035 SM June 08 CHAPTER 9 AIR CLEANER...

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Page 145: ...own away rapidly from the body tube and after passing from hopper slot they fall in the dust collector the precleaned air then passes through paper filter element before entering the engine A safety c...

Page 146: ...F of air cleaner 9 And remove cover G 10 Remove Primary Element H Remove Secondary Element Inner Element ONLY if it is to be replaced DO NOT attempt to clean Secondary Element If Secondary Element is...

Page 147: ...sure rubber sealing surfaces are in good condition on both ends If damaged replace element d Before you install Primary Element clean the inside of air cleaner housing unloader valve with a damp clot...

Page 148: ...type indicator set to 80 milli bar vacuum in intake system The red band will be visible in the transparent cover when the 80 milli bar vacuum is reached At this stage air cleaner has to be cleaned Ser...

Page 149: ...35 Series 4WD Model 3535 4035 4535 and 5035 SM June 08 CHAPTER 10 FUEL SYSTEM...

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Page 151: ...3 Raise the hood and disconnect the battery 4 Remove the battery 5 Remove the scuttle panel and the filler plate 6 Carefully free the instrument panel Disconnect the oil pressure pipe from the gauge T...

Page 152: ...working properly D Installation 1 Reverse the removal procedure 2 Fill the tank with clean fuel and bleed the system in the following sequence E FUEL TAP VALVE The Fuel Tap 1 2 is located between the...

Page 153: ...pump untill all air is displaced Tighten the connection 4 Release the air bleed screw on the injection pump and again use the hand primer untill all air is displaced Tighten the connection 5 Repeat o...

Page 154: ...lation 1 Reverse the removal procedure 2 Bleed the fuel system G INJECTORS 1 Description The performance of the modern High speed engine depends largely upon proper functioning of its fuel injection s...

Page 155: ...creased fuel consumption 3 Overheating 4 Loss of power 5 Engine knocking misfiring and uneven running However complaints of the above nature may not be solely due to malfunctioning of the nozzles Othe...

Page 156: ...moval procedure using New copper washer and tighten to the specified torque Be sure that the fuel overflow banjo in the injector is towards the front of the engine After the assembly of the injector n...

Page 157: ...njection System from Authorised Dealer before installation d Installation 1 Reverse the removal procedure ensuring that the key in the gear is in engagement with the keyway in the pump flange and that...

Page 158: ...n Fig 1 3 Rotate crankshaft pulley in clockwise direction as seen from flywheel side till the pointer matches with crankshaft pulley groove Ensure first cylinder piston at compression TDC 4 Set dial g...

Page 159: ...t attempt to handle the pump lift it holding the IKSB unit 5 When the vehicle fails to start in cold condition check if the 12V is connected to IKSB solenoid Check if battery voltage is 12V 6 During h...

Page 160: ...C 104 35 Series 4WD Model 3535 4035 4535 and 5035 SM June 08 Fuel System Fuel Injection Pump Calibration Chart 3535...

Page 161: ...C 105 35 Series 4WD Model 3535 4035 4535 and 5035 SM June 08 Fuel System Fuel Injection Pump Calibration Chart 3535...

Page 162: ...C 106 35 Series 4WD Model 3535 4035 4535 and 5035 SM June 08 Fuel System Fuel Injection Pump Calibration Chart 4035...

Page 163: ...C 107 35 Series 4WD Model 3535 4035 4535 and 5035 SM June 08 Fuel System Fuel Injection Pump Calibration Chart 4035...

Page 164: ...C 108 35 Series 4WD Model 3535 4035 4535 and 5035 SM June 08 Fuel System Fuel Injection Pump Calibration Chart 4535...

Page 165: ...C 109 35 Series 4WD Model 3535 4035 4535 and 5035 SM June 08 Fuel System Fuel Injection Pump Calibration Chart 4535...

Page 166: ...C 110 35 Series 4WD Model 3535 4035 4535 and 5035 SM June 08 Fuel System Fuel Injection Pump Calibration Chart 5035...

Page 167: ...C 111 35 Series 4WD Model 3535 4035 4535 and 5035 SM June 08 Fuel System Fuel Injection Pump Calibration Chart 5035...

Page 168: ...35 Series 4WD Model 3535 4035 4535 and 5035 SM June 08 Group D C l u t c h Clutch D1 D10...

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Page 170: ...ragm spring Mutual 0 020 in difference 2 SPECIFICATIONS 1 Make Valeo 2 Type of clutch Single Plate Diaphragm Spring Dry ceramic pad 3 Main drive member in 11 Clearance 1 Release bearing to release fin...

Page 171: ...ly of PTO damper 2 Fit PTO damper D 4 Remove PTO clutch damper 2 REMOVAL REFITMENT OF CLUTCH FROM TRACTOR REMOVAL 1 Separate front axle with engine from clutch housing 2 Remove clutch assembly by loos...

Page 172: ...are provided to prevent excessive movement of pressure plate 4 REMOVAL 1 To remove the clutch engine must be separated from the clutch housing Apply parking hand brake and wedge to rear tire 2 For spl...

Page 173: ...facing rivet on to pressure plate and flywheel face if so re machine flywheel face re machine pressure plate Machining can be done without dismantling the clutch cover assy care to be taken to prevent...

Page 174: ...ywhere between the flywheel face and straight edge in any of the checking positions repairs or replacement is necessary i Machining can be made without disassembling the clutch cover Care to be taken...

Page 175: ...embly 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 8 3 Take 4 nos...

Page 176: ...drive strap and rivet head after riveting 3 Form riveted head dia 10 11 min 8 INSTALLATION a THE SINGLE PLATE CLUTCH 1 A pilot tool which will slide through the bore of the driven member and locate i...

Page 177: ...nsmission 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...

Page 178: ...3535 4035 4535 and 5035 SM June 08 Group E Tr a n s m i s s i o n Transmission E3 E22 Rear Axle E23 E30 Differential E31 E44 Differential Lock System E45 E50 Rear PTO Cover E51 E54 Wet Clutch PTO E55...

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Page 180: ...35 Series 4WD Model 3535 4035 4535 and 5035 SM June 08 CHAPTER 1 TRANSMISSION...

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Page 182: ...w 0 007 0 012 Medium 0 007 0 012 High 0 007 0 012 Bull Gear Pinion 0 005 0 010 2 FLOATS Sr Location Float in Inch Assembly Method No Minimum Maximum 1 Between gear reverse driving 0 004 0 008 Graded S...

Page 183: ...To Transmission Case Flange Bolt M8 x 16L x 1 25 21 25 11 Stopper Wet PTO Clutch Flange Bolt M8 x 16L x 1 25 21 25 12 Upper Cover Transmission Case Flange Bolt M10 x 25L 41 50 13 Rear Cover To Transmi...

Page 184: ...k M8 21 25 33 Bolt Spring Retention M16 x 1 5 50 60 34 Bolt Hex M10 Idler Shaft 4WD M10 x 1 25 41 50 Reverse 35 Bolt Special 4WD Shaft Retention M8 21 25 36 Connector Dipstick M33 x 1 5 50 60 37 Magne...

Page 185: ...Shifting Shifter fork worn out or Replace damaged Shifter fork bent Replace Synchronizer unit damaged Repair or Replace 4 Gears clash Improper Clutch Setting Adjust or Repair when shifting Synchronize...

Page 186: ...5035 SM June 08 Transmission FORWARD REVERSE Major Components 1 Engine Flywheel 2 Clutch Assembly A Transmission Drive Shaft B P T O Drive Shaft C Speed Driving Shaft D Forward Reverse Synchronizer E...

Page 187: ...D to Counter Shaft J Reverse Gear Power Flow Rotary power from Transmission Driving Shaft A flows to Counter Shaft J as per following flow Transmission Driving Shaft A to Reverse Driving Gear H to Rev...

Page 188: ...2nd Synchronizer L It equalizes the speed of the involved shafts before the shifting ring engage Shifting Ring engaged with 1st Gear The power flows from Counter Shaft J integral gear 1st Gear Driving...

Page 189: ...ifter Ring engaged with 3rd gear The power flows from Counter Shaft J 3rd Gear Driving S to 3rd Driven Gear U on Speed Shaft C to the Synchronizer R splined with the Speed Shaft Hence power goes to Ra...

Page 190: ...Constantmesh The power from Speed Section comes through range shaft through range section The High and Medium range driving gears are splined to Range Shaft and low gear is integral with the Range Sh...

Page 191: ...g G Medium Gear Driven H Low Gear Driving I Low Gear Driven Shift Coupling Engaged with Medium gear The power from Range Shaft medium driving gear F flows to medium driven gear G through Coupling C to...

Page 192: ...emove steering gear and brake linkages as well as shifting linkages and other fitment 4 Support the clutch housing with suitable arrangement 5 Remove clutch release bearing A shaft B and fork C 6 Remo...

Page 193: ...verse idler shaft positioning bolt I and remove idler circlip J and assembly by slight tapping 11 Remove forward Reverse and speed levers K 12 Separate forward Reverse and speed forks removing spring...

Page 194: ...Remove rear bearing internal circlip and bearing by special tool 23 Remove front external circlip on counter shaft Keep it in secured place 24 Tap the counter shaft slowly during pushing the counters...

Page 195: ...C All bearings bushes shaft to be lubricated with specified oil for assembling 3 Assemble the speed top shaft 4 Assemble shuttle shift assembly in the housing 5 Insert Speed Top Shaft from rear end th...

Page 196: ...with specified value E Forward Reverse Section RAIL FITTING 1 Insert special tool in clutch housing from inside 2 Slide rail from front side 3 Assemble Forward Reverse fork without ball 4 Align specia...

Page 197: ...Remove Hydraulic Lift Housing and Range Section top plate NOTE Place the Transmission case with axle on suitable stand and suitable support at front before starting work on Range Section 5 Remove the...

Page 198: ...ap the Range shaft from rear end Hold the high and medium gears After the Range shaft removal take out the gears NOTE Removal of Spline shaft refer differential assembly D Rail Fitting Range Section 1...

Page 199: ...emove 4WD idler gear needle bearing and two thrust washers 5 Remove bolt shaft retention 4WD rail 6 Tap the rail from rear side and remove from front side of transmission case 7 Remove lock plate 8 Ta...

Page 200: ...35 Series 4WD Model 3535 4035 4535 and 5035 SM June 08 CHAPTER 2 REAR AXLE...

Page 201: ......

Page 202: ...ial LH 11 Gear Crown Wheel 12 Differential Pinion Shaft 13 Bevel Gear Differential RH 14 Bull Gear RH 15 Ball Bearing 16 Rear Axle Assembly RH 17 Ball Bearing 18 Rear Axle 19 Ball Bearing 20 Oil Seal...

Page 203: ...e bull pinion shaft meshes in differential bevel gear and other end is with brake plate Hence the power is transmitted to axle shaft from differential section through bull gear pair 2 Removal 1 Front...

Page 204: ...ling 8 Remove securing bolts A of Rear Axle Housing 9 Ease the axle away from transmission case NOTE Removal Assembling of LH RH axle are same 3 Dismantling 1 Remove the bolt shims and lock plate and...

Page 205: ...NOTE Check ball bearing and oil seal for damages and pitting if require replace it 4 Cleaning and Inspection 1 Clean all parts with suitable solvent 2 Inspect bearing for wear pitting or damage 3 Ins...

Page 206: ...end ball bearing in Real Axle Carrier RAC and lock with circlip H 2 Clean retainer surface area and fit new oil seal in retainer Rear Axle 2 nos 3 Install oil seals with retainer in Rear Axle 4 Instal...

Page 207: ...with copper Hammer till big end bearing rest on inside spacer and put shims spacer and lock plate and bolt Torque the bolt with the specified values NOTE New oil seal should be used while reassembly a...

Page 208: ...35 Series 4WD Model 3535 4035 4535 and 5035 SM June 08 CHAPTER 3 DIFFERENTIAL...

Page 209: ......

Page 210: ...tion of Axle Shaft 10 The Differential Housing Assembly consists of two Bevel Gear LH RH two pinion and one shaft When tractor takes a turn one axle moves faster than other This results in rotation of...

Page 211: ...spacer between transmission splined shaft bearing head and machine surface of the housing The differential lock unit is incorporated which is controlled by a foot pedal as assembled at the right hand...

Page 212: ...pivoting c Remove the rear axle housing d Remove the brakes as detailed in Brakes e Remove hydraulic housing and sheet metal If you are working on spline shaft or differential lock f Remove LH Rear A...

Page 213: ...ould slide easily on spline shaft but no excessive side play Check sliding couplings and gear for burrs and broken teeth and worn out e Check the shifter rails and forks for straightness wear of poppe...

Page 214: ...w their original position b Check the differential pinion thrust bearing and pinion shaft for excessive wear pitting or teeth damaged If these parts are damaged or excessively worn replace as a set c...

Page 215: ...and lock the lock washers h Press the taper roller bearing cone on left side i Install differential lock coupling and press taper roller bearing cone of RH side 8 Installation of Differential Case As...

Page 216: ...Remove 4WD shifting assembly and 4WD output shaft assembly 10 Assembly of Spline Shaft NOTE Spline shaft preloading to be done after installing all Range Driven Gears 1 Install taper roller bearing co...

Page 217: ...2 Loop both ends of a piece of string and slip on loop round the differential case opening Then Wind the string around the differential housing Secure a spring balance into the free end as shown in f...

Page 218: ...ery of the ring gear 6 Check the contact if not proper according to the instructions below More than 35 red lead contact are on the gear tooth surface The center of both contact a 1 3 of the entire wi...

Page 219: ...e shaft forward and noting the reading NOTE 1 Several measurements should be taken rotating the shaft at each reading 2 Ensure that the extreme length of travel is reached in each direction 6 As the p...

Page 220: ...one centre distance is etched on the machined face of the pinion Also etched on this face is the set number of the pinion and bevel gear Ensure that the pinion and bevel gear are matched NOTE Spline s...

Page 221: ...08 1 Spline Shaft 2 Pinion Differential Case 3 Differential Case 4 Bull Pinion Brake Shaft LH 5 Bevel Gear Differential LH 6 Gear Crown Wheel 7 Differential Pinion Shaft 8 Bevel Gear Differential RH 9...

Page 222: ...35 Series 4WD Model 3535 4035 4535 and 5035 SM June 08 CHAPTER 4 DIFFERENTIAL LOCK SYSTEM...

Page 223: ......

Page 224: ...ling pins aligned with the holes on the bevel gear get inserted into the bevel gear Since the bull pinion shaft is coupled with spline bevel gear no differential action takes place and both bull pinio...

Page 225: ...dure given in differential section b Remove differential lock pedal shaft A by removing spring pin B c Use Special Tool C to remove spring pin d Remove fork spring lock pin D e Hold spring and differe...

Page 226: ...O rings and oil seals a Fit oil seal at LH side b Insert differential lock shaft assemble spring c Assemble fork locating in differential lock coupling d Insert spring dowel near fork e Insert washer...

Page 227: ......

Page 228: ...35 Series 4WD Model 3535 4035 4535 and 5035 SM June 08 CHAPTER 5 REAR PTO COVER...

Page 229: ......

Page 230: ...embly in stud locator Slowly push the assembly and precaution to be taken for wet clutch assembly matches with the hub properly to avoid damage of liners c After assembly check smooth rotation of wet...

Page 231: ......

Page 232: ...35 Series 4WD Model 3535 4035 4535 and 5035 SM June 08 CHAPTER 6 WET CLUTCH PTO...

Page 233: ......

Page 234: ...pline for damage and burrs b Check bearing for pitting and crack if any c Replace all seals d Check wet clutch liners for wear e Clean all parts with suitable solvent 3 ASSEMBLY PTO COVER a Assemble o...

Page 235: ...rclip NOTE Align lubrication hole of wet clutch body and input shaft hole c Assemble the seal ring carefully by using special tool i e Sleeve d Assemble the above sub assembly in PTO cover and retain...

Page 236: ...35 Series 4WD Model 3535 4035 4535 and 5035 SM June 08 CHAPTER 7 BRAKES...

Page 237: ......

Page 238: ...ctuating plate Replace uneven wear Brake pedal return spring weaken Replace or broken Brake pedal shaft sticky on bushes Clean Lubricate 3 Poor Braking Brake pedal free play excessive Adjust Brake dis...

Page 239: ...and Brake Bolt When Pedal is pressed Actuating Lever gets activated which in turn activates Actuating Disc The actuating disc expands with the guide of Rear Axle Carrier Housing and Brake Pin and Brak...

Page 240: ...nical linkages The parking brake is a mechanical type Pulling the parking brake lever results in the same state as that obtained when the brake pedal are pressed Although wet disc get worn out by appr...

Page 241: ...ench for further dismantling b Loosen bolt A and take out cover plate B c Remove friction disc C actuating disc assembly D and intermediate pin E d Remove retainer F from other side by loosening the b...

Page 242: ...ged dents found replace the friction plate c Inspect the linkage for wear NOTE Discard the actuating disc spring if found weak or end are deformed d Replace the worn or faulty parts NOTE Removal disma...

Page 243: ......

Page 244: ...35 Series 4WD Model 3535 4035 4535 and 5035 SM June 08 Group F Fr o n t A x l e Front Axle F1 F25...

Page 245: ......

Page 246: ...where the power is divided into right and left and to the respective final drives In the final drive the transmitted revolution is reduced by the bevel gear to drive the front wheel The 4WD mechanism...

Page 247: ...2 3 4 5 6 7 8 9 10 11 1 Incorrect installation defective axle Correct installation or repair or replace the differential in case it does not survive any one of the test phases 2 Overloading incorrect...

Page 248: ...on and ring 1 Prolonged functioning at high temperatures 2 Incorrect lubrication 3 Low oil level 4 Contaminated oil 1 Excessive use 2 Insufficient lubrication 1 Vehicle over loaded 2 Vehicle s acciden...

Page 249: ...omponents 1 Excessive use 1 Insufficient lubrication 2 Incorrect lubrication 3 Contaminated oil 1 Excessive use 2 Excessive pinion axial back lash 3 Insufficient lubrication 4 Contaminated oil 1 Vehic...

Page 250: ...or adjust usually heard when vehicle see above moves in neutral gear but are not loud 2 Incorrect back lash between 2 Replace pinion and ring sound heard while decelerating disappears while increasin...

Page 251: ...UNF 85 90 100 9 Differential case To Ring Gear BOLT 7 16 20 UNF 23 90 100 10 Pillow Block Front To Beam Housing NUT M16 60 70 11 Swivel Housing Allen Bolt M8 x 1 25 x 16 25 35 12 Beam Housing To Front...

Page 252: ...ve the front and rear pillow block bolts and front axle can be separated 5 Remove front and rear pillow blocks INSPECTION Front Rear Pillow Block Mounting Diameter 1 Measure the diameter at a bush con...

Page 253: ...SMANTLING 1 For separating final reduction gear from hub housing remove bolt from spindle front axle Remove washer and take out the spindle 2 Support hub housing on flange and then press final reducti...

Page 254: ...components Number of shims and thickness to be noted down for both side and preserve it for assembly Take the bearing out of the differential half box using two levers or three hold extractor F PINIO...

Page 255: ...al B in Hub Housing NOTE Apply Grease on oil seal before fitment in housing 3 Press bearing C 4 Put bearing retainer D and torque the mounting bolt to 25 Nm 5 Put spacer E in another side of hub housi...

Page 256: ...ully 8 Insert final bevel gear H and retainer spindle axle washer 9 Lock the spindle axle by tightening bolt I to the specified torque 65 Nm 10 Lock the bolt by bending washer J at three places near b...

Page 257: ...ng temperature 120 C 2 Fit the side housing pivot bearing C 3 Press the oil seal D NOTE Apply grease to oil seal before fitment 4 Fit locating Dowels E and Studs F and torque the studs to 55 65 Nm 5 F...

Page 258: ...earing on intermediate pinion 2 Insert the intermediate reduction gear A with bearing through slots provided in side housing and assemble in position 3 Assemble intermediate pinion B with bearing and...

Page 259: ...t shims A between swivel housing hub housing and tighten both assemblies mounting bolt B to torque 41 50 Nm 3 Apply thread sealant on swivel housing and fit final reduction pinion with bearing C insid...

Page 260: ...Y OF HUB SWIVEL SIDE HOUSING 6 Lift the side housing and fit to swivel housing by slight tapping 7 Press oil seal F inside top cover G 8 Fit top cover to side housing by slight tapping and tighten the...

Page 261: ...SSEMBLY 1 Insert bearing A on spiral bevel pinion B NOTE Temperature of bearing 120 C 2 Place the housing input shaft C on a flat surface 3 Press the outer cone of bearing to both side of housing inpu...

Page 262: ...n 3 0 to 3 75 Kg If the preload is within limit or more accordingly add or remove the shims 9 Once the preload set and shim value decided remove lock nut Put O ring H on pinion by using plastic sleeve...

Page 263: ...differential bevel gear B with thrust washer C in RH Differential case 3 Assemble differential bevel pinion D with thrust washer 2 Numbers 4 Insert shaft differential E and position with spring pin F...

Page 264: ...e bolts with washer by bending it on bolt head 10 Fit the taper roller bearing K temp 120 C on LH differential case 11 Fit the cone L into bearing carrier M with taper roller bearing N NOTE The taper...

Page 265: ...he bolts to 45 Nm torque 14 Check preload and add or remove shims till you get desired preload Preload Differential case 1 25 to 2 Kg 15 Fit Pinion assembly to Differential case assembly and tighten t...

Page 266: ...2 Mount differential carrier assembly to the beam housing and tighten bolts A to 120 Nm torque 3 Put o ring B on beam housing both ends NOTE Apply grease to o ring before fitment 4 Insert shaft beam h...

Page 267: ...uard for steering cylinder 11 Assembly power cylinder G on beam housing and tighten it to torque 140 Nm 12 Fit tie rod ball joint assembly H to power cylinder and top cover Tighten these joints I to t...

Page 268: ...g 16 Collar Oil Seal 17 Hex Bolt 18 Ball Bearing 19 Swivel Housing LH 20 Drain Plug 21 Shaft Side Housing 22 Ball Bearing 23 Oil Seal 24 Ball Bearing 25 Ring Gear 26 Taper Roller Bearing 27 O Ring 28...

Page 269: ...35 Series 4WD Model 3535 4035 4535 and 5035 SM June 08 Group G E l e c t r i c a l Electrical System G1 G28...

Page 270: ......

Page 271: ...ce 3 Wiring harness loose connected 3 Repair or replace between battery positive terminal and alternator terminal 4 Cooling fan belt slipping 4 Adjust tension ALTERNATOR 1 Defective Regulator 1 Replac...

Page 272: ...gulator 4 Alternator drive belt loose 4 Adjust belt if necessary replace 5 Surging of engine speed 5 Adjust engine speed setting 6 Slip ring dirty 5 Clean Test lamp connect to F and ve of Alternator 1...

Page 273: ...ive 2 Check earth cable battery to starter cable and batteries connecting cable for secure mounting to terminals Replace cables if necessary 3 Starter relay defective 3 Replace 4 Safety switch defecti...

Page 274: ...switch Replace defective 4 Short circuit between engine oil Repair pressure switch lead and chassis 1 Engine oil pressure switch defective Replace 2 Warning harness disconnected Repair or Replace or...

Page 275: ...switch defective Replace 2 Flasher unit defective Replace 3 Bulb blown Replace 4 Fuse blown Replace 5 Hazard switch defective Replace 6 Switch Instrumental cluster Replace defective 1 Fuse blown Repla...

Page 276: ...roper 1 Fuse blown Replace 2 Wiring harness disconnected or Replace improperly connected Between head light switch terminal and tail light 1 Fuse blown Replace 2 Bulb blown Replace 3 Wiring harness di...

Page 277: ...ace 1 Short circuited heavy over load Repair or replace 1 Timer relay faulty Replace the timer 2 Wiring faulty Repair or replace KSB 1 KSB FIP circuit faulty Replace 2 KSB Relay faulty Replace 3 Wirin...

Page 278: ...Indicator 10 4WD Indicator 11 Parking Brake Indicator 12 Heater Indicator 2 Instrument Cluster A General The various Instruments gauges and switches are mounted on the instrument panel and scuttle ass...

Page 279: ...This is a Digital Hour Counter located in the RPM meter It is operated by pulses coming from Alternator when the engine is running Hour counter displays the cumulative engine running hours Fuel Gauge...

Page 280: ...t glows when either brakes or Parking Brake is applied 4WD Indicator It glows when 4WD is engaged Battery Charging Indicator This indicator will glow if battery is not getting charged Once the engine...

Page 281: ...ch 3 Combination Switch 4 Light Switch 5 Horn Push Button 6 Turn Signal Switch 7 Hazard Switch 8 Starter Key Switch 9 PTO AUTO MANUAL OFF Switch Hazard Switch The piano type switch is located below th...

Page 282: ...inate high beam of head lamp Parking Lamp Turn Signal Switch This is 3 positions rotary switch The vertical position of knob operates in both directions and the positions are as follows 1 Vertical OFF...

Page 283: ...Auto and Manual Mode switch will be activated when the PTO Engage Disengage Switch is in ON position 2 Alignment of Auto mark with pointer Operates AUTO mode This switch can be used when the PTO Engag...

Page 284: ...e PTO shaft can prove fatal POWER TAKE OFF PTO is operated by electrically PTO can be operated by using a combination of PTO Engage Disengage Switch and PTO Mode Switch After switching ON the PTO Enga...

Page 285: ...Front View 1 Turn Signal Lamp RH 2 Parking Lamp RH 3 Head Lamp RH 4 Turn Signal Lamp LH 5 Parking Lamp LH 6 Head Lamp LH Rear View 1 Plow Lamp 2 Turn Signal Lamp LH 3 Reflector Rear Position Lamp LH 4...

Page 286: ...correct type of fuse as shown on the fuse box cover b 4 extra fuse links one each have been provided in the side fuse box cover To remove this extra fuse from cover press the link from contact point...

Page 287: ...to lead peroxide and the negative plates to lead sponge In this process the acid becomes more highly concentrated and so its specific gravity rises As the battery is discharged the active material on...

Page 288: ...d with the drive and centre is supported on the eccentric pin pushes the drive into mesh with the flywheel ring gear when the solenoid is energised At the end of the travel of the plunger a pair of co...

Page 289: ...mmet 18 Nut Pivot 19 Pivot Pin 20 Fixing Bracket Assembly 21 Bearing Bush Fag Bakt 22 Bearing Bush Inter Bakt 23 Operating Plate Pinion 24 Drive Assembly 25 Thrust Collar 26 Jump Ring 27 End Cover 28...

Page 290: ...inding and a thinner gauge winding called hold on or shunt winding The pull in winding is connected through the field coil and armature to the ground Whereas shunt is connected between smaller termina...

Page 291: ...elly on terminal tight all connection 4 Defective Starter Motor 4 Replace the Starter Motor B Starter crank 1 Check the battery condition 1 Substitute a fully charged battery but engine 2 Check the fu...

Page 292: ...oltage control is provided via a built in electronic regulator An RFI suppression capacitor is provided across the positive and negative terminals A phase terminal can be made available if required 3...

Page 293: ...5000 rpm Adjust the load so that Terminal voltage is between 13 0 to 13 5 Volts The Ammeter should read the rated output 9 Run the Alternator at 6003 rpm and adjust the loads to 18 Amps The volt meter...

Page 294: ...T TENSION IF FOUND SLACK ADJUST THE BELT DEFLECTION TO BE 10 15MM WHEN PRESSED MIDWAY AT THE LONGEST POINT BETWEEN PULLEYS REFER FIGURE BELOW AND CHECK FOR CHARGING IF THE UNIT IS STILL NOT CHARGING R...

Page 295: ...35 Suction Connector Screw 36 Sealing Washer 37 Suction Connector Assy 38 Dust Cap 39 Dust Cap 40 Sealing Washer 41 Check Valve Assy 42 Housing M C 43 Screw 44 Centre Plate M C 45 O Ring 46 O Ring 47...

Page 296: ...Wiring Diagram 35 Series G 28 35 Series 4WD Model 3535 4035 4535 and 5035 SM June 08...

Page 297: ...35 Series 4WD Model 3535 4035 4535 and 5035 SM June 08 Group H S t e e r i n g Steering H1 H19...

Page 298: ......

Page 299: ...nch3 rev 100 cc rev 4 Relief valve setting 100 Bar 5 Rated flow 19 lpm b Pump 1 Make EATON 2 Type Gear 3 Displacement 8 cc rev c Cylinder 1 Type Double acting balanced 2 Bore 63 mm 2 48 in 3 Rod 38 mm...

Page 300: ...TINGS 6 7 7 8 3 8 2 5 5 5 2 9 9 3 5 4 1 1 Pipe Steering Pressure From Pump To Hose 2 Adaptor T L Port Of HSU Series 5 3 Adaptor P R Port On HSU 4 Steering Control Unit 5 O Ring for P L R T Ports of HS...

Page 301: ...column cover Disconnect the wiring harness to PTO engaging switch 5 Dismantle the scuttle cover 6 Remove linkages of hand accelerator and forward reverse 7 Loosen bolts of HSU Bracket 8 Loosen hose co...

Page 302: ...do not mix water is considered a foreign chemical contaminant Any surface in contact with hydraulic fluid must be clean and dry Recommended Practices for Handling and Storage of Hydraulic Components...

Page 303: ...H 7 35 Series 4WD Model 3535 4035 4535 and 5035 SM June 08 STEERING SYSTEM CIRCUIT Steering...

Page 304: ...manual pump The resistance of the wheels determines the steering effort required by the operator to develop the necessary hydraulic pressure at the steering cylinder piston to turn the wheels The man...

Page 305: ...oes directly to the steering cylinder i Turning The initial turn of the steering wheel driving the attached manual pump moves the control valve spool and opens the port to the manual pump and the stee...

Page 306: ...eplacement B ASSEMBLING THE STEERING PUMP Always use new O Rings Damaged or used O Rings will leak 1 Place new O Rings on pump flange Install pump on engine 2 Install cap screws for connecting the Hyd...

Page 307: ...ed out 5 Maintain recommended oil level in reservoir and assemble reservoir cap 7 TIPS FOR MAINTAINING THE HYDROSTATIC STEERING SYSTEM Top up fluid level in reservoir transmission housing if necessary...

Page 308: ...peller shaft towards axle first and then slide away from the axle m Remove mounting bolts holding axle to semi chassis n Move the axle away from the tractor o Remove both connecting links connected to...

Page 309: ...engine running at govern speed operate the steering for approximately five minutes d With the engine stopped it should be possible to rotate the steering from straight ahead to full lock in approximat...

Page 310: ...tervals observed Specified oil grading Discolouration or flaking of paint coating on tandem pump due to over heating of oil Mechanical damage wheel bearings steering knuckles ball joints etc Should th...

Page 311: ...der head 2 Gently tap by plastic hammer the rod till the cylinder head will come out 3 Remove cylinder head 4 Inspect cylinder head rod wiper rod seal bearing ring and o ring for wear or cracks 5 Remo...

Page 312: ...into external leakages free wheeling problem Steering Cylinder Refitment 1 After installing new seals and o ring on piston and cylinder head tap gently by plastic hammer the rod to align it to cylinde...

Page 313: ...alve between cylinder lines or ports Worn steering control unit meter Replace steering control unit Thermal Shock Check unit for proper operation and cause of thermal shock 9 TROUBLE SHOOTING Most ste...

Page 314: ...flow to steering unit can be caused by 1 Low fluid level Add fluid and check for leaks 2 Ruptured hose Replace hose 3 Internal steering control unit Replace the unit damage due to thermal shock Leakin...

Page 315: ...00 psi Large particles can cause Clean the unit and filter the oil binding between the spool If another component has failed and sleeve generating contaminants flush the system while bypassing the ste...

Page 316: ......

Page 317: ...35 Series 4WD Model 3535 4035 4535 and 5035 SM June 08 Group I H y d r a u l i c s Hydraulics I1 I37 Auxiliary Valve I38 I40...

Page 318: ......

Page 319: ...es i Position and Draft Control ii Lowering speed adjustment of Lifting Arm iii Common oil for Transmission Hydraulic and Power Steering iv Common Relief Valve for Hitch Valve Auxiliary Valve and Load...

Page 320: ...Hydraulics 2 HYDRAULIC CIRCUIT 1 Suction Strainer 2 Suction Filter 3 Hitch Pump 4 Steering Pump 5 System Relief Valve Block 6 Auxiliary Valve 7 Hydraulic Lift Unit 8 Power Steering Control Unit 9 Powe...

Page 321: ...tors are equipped with hydraulic system consist of an engine driven gear pump lift housing connecting pipes and the filter The reservoir is transmission housing The oil used is common for transmission...

Page 322: ...hrough hole 16 Thus allowing the same valve to open hole 28 which discharges chamber 15 by means of the duct 29 of the regulator piston 2 Thus the oil coming from the pump feeds chamber 22 and allows...

Page 323: ...lows to the cylinder through the annular duct 19 enters in hole 20 through the fixed throat 6 and the variable throat made by the control spool 1 with the hole 21 opens the check valve 3 enters in the...

Page 324: ...15 that opens the discharge holes 17 causing oil to flow to the tank At the same time the oil from the cylinder under pressure chamber 23 enters in the annular duct 18 passes through the holes 32 the...

Page 325: ...ywheel will transmit an anticlockwise rotation by means of friction shock absorber 8 to the transmission lever 9 that will bring distributor shaft 21 into delivery position C thus causing the arms to...

Page 326: ...sion rod 23 causes lever 9 to rotate clockwise thereby compressing the spring of friction shock absorber 8 and thus releasing shaft 21 which now can move to the neutral position N where it is pushed o...

Page 327: ...on so that roller 11 acting on the draft cam 12 will move the distributor shaft 21 into the lifting position C and causing a further upward movement of the lifting arms 2 Due to the position previousl...

Page 328: ...movement is proportional to the movement range fixed by means of lever 1 6 USE OF CONTROL LEVERS B DRAFT CONTROL LEVER 2 Move the position control lever 1 fully down have the implement penetrated into...

Page 329: ...ll the lower links slightly start raising The rockshaft operates under controlled draft but at the same time it prevents the implement from excessively penetrating into the ground causing a not very u...

Page 330: ...TMENT OF POSITION CONTROL LEVER The adjustment is carried out in order to establish the maximum raised position of the rockshaft s lifting arms Completely lower the arms and apply a light weight which...

Page 331: ...y to have a safety margin of 10 15 mm In order to do this rotate slowly in a clockwise direction the shaft 5 until the arms are lowered by the required safety margin At this point keep the shaft 5 fix...

Page 332: ...ust be carried out without implements or loads applied to the three point linkage 20 i e in a neutral position Position the two control levers 1 and 2 in the lowest position With the motor running at...

Page 333: ...l play completely d MEASUREMENT CONTROL OF INTERNAL PUSH ROD If the rockshaft is disassembled and if the regulator R must be changed it is advisable to control the measurement X 15 in order to re asse...

Page 334: ...ulics Cap Screw Hydraulic Housing to Transmission Case 41 50 Nm 30 37 Lb ft Control Support Quadrant Linkage Screw 19 29 Nm 14 21 Lb ft Bracket Synchro Lubrication Mounting Bolt 8 10 Nm 6 7 Lb ft Comp...

Page 335: ...5 SM June 08 Hydraulics Control Support Assembly Mounting Screw 19 29 Nm 14 21 Lb ft Crank Locking Screw 19 29 Nm 14 21 Lb ft Cylinder Mounting Set Screw 98 127 Nm 72 94 Lb ft Cylinder Mounting Set Sc...

Page 336: ...5 SM June 08 Hydraulics Tie Rod Mounting Screw 19 29 Nm 14 21 Lb ft Top Link Bracket Mounting Screw 39 49 Nm 29 36 Lb ft Top Link Bracket Mounting Screw 39 49 Nm 29 36 Lb ft Control Valve Mounting Scr...

Page 337: ...ot correct feels the load without the functioning of the over pressure valve The rockshaft does not Faulty adjustment of the Adjust position control descend over its entire position control lever 1 le...

Page 338: ...raised height oscillation with the engine causes the internal off the load does not lower automatic back stop to function Working with the draft Sensitivity of the Control Adjust the sensitivity of t...

Page 339: ...sheet assembly Removing of Control Levers Knob Hydraulics 1 Remove rear isolator mounting bolt 2 Then remove rear platform to front platform 3 Remove the PC DC Range Speed Lever Knobs 4 Remove diff lo...

Page 340: ...the hydraulic unit assembly 15 Make repairs as necessary 16 Clean mating surfaces of housing assembly and differential housing using primer 17 Install hydraulic lift unit using cap screws Torque the b...

Page 341: ...L HYDRAULIC CONTROL LEVER SUPPORT ASSEMBLY 1 Remove Hydraulic Lift Unit as per the guided procedure 2 Remove position and draft control linkages levers by loosening lock clips and washers 3 Remove soc...

Page 342: ...f clutch hub fits between tabs on control lever 10 Install nylon bushings into clutch hubs and install hubs to control lever and pitman arm Hand tighten adjusting screw 11 Install new O ring onto shaf...

Page 343: ...r the guided procedure NOTE To access links inside hydraulic lift assembly housing lift assembly must be placed upside down 2 Remove cylinder by loosening two allen set screws A B 3 Remove cylinder fr...

Page 344: ...s N and take out control lever support assembly 9 Remove roll pin O of cam P and snap ring 10 Remove capscrew Q of tie rod R and pin assembly S NOTE Inspect bushings for wear or damage Replace as nece...

Page 345: ...ckshaft control valve 5 Install new rate of drop valve and tighten bolts to specified torque 19 29 Nm 14 21 Lb ft 6 Install seat 7 Operate hydraulic 8 Fill transmission hydraulic oil as per the recomm...

Page 346: ...en in point no 11 2 Remove position and draft control linkages levers by loosening lock clips and washers 3 Rotate lift arms to access and remove setscrew A in crank B 4 Remove snap ring C and arm D f...

Page 347: ...shing without bushing flush with outer edge of inner bore using a bearing bushing and seal driver set 11 Apply clean transmission hydraulic oil to all internal parts 12 Install link to crank with spri...

Page 348: ...ntrol linkages levers by loosening lock clips and washers 3 Remove two allen screws A B to loosen the cylinder 4 Remove bolt C of bracket lubrication D and take it out 5 Remove cylinder assembly E 6 I...

Page 349: ...ulics 8 Replace seal ring G of piston 9 Apply clean transmission hydraulic oil to piston and inner walls of cylinder 10 Install piston with concave end facing opening of cylinder 11 Apply thread seala...

Page 350: ...arate it Replace as necessary with spring and cover assembly loosen two screws E and one set screw F out top link bracket 1 Loosen screw A of tie rod B 2 Remove nut C of top link bracket D to 3 Check...

Page 351: ...r L lift unit 10 After complete assembly grease through grease nipple provided on control support sleeve and top link bracket 6 Remove special allen screw I to check spring 7 Check any wear or damage...

Page 352: ...SSEMBLY Removal 1 Loosen the connections to relief valve as shown in fig for further replacement Refitment 1 Assemble the connections to relief valve Service Recommendation It is not recommended to re...

Page 353: ...synchroniser and spline shaft c Theory of Operation Refer Circuit I 4 When the PTO ON OFF button is in OFF position all the oil enters through P port and leaves through L port for the lubrication of W...

Page 354: ...RH side of the rear axle and jack up the tractor 3 Remove auxiliary valve knob A and then remove auxiliary valve cover B 4 Disconnect aux valve inner cable C from lever assembly by removing pin D cott...

Page 355: ...bolt from adapter fitted on C T ports 12 Loosen adapter P Q from C T ports and immediately plug the ports Preserve the adapters and washers 13 At this stage Auxiliary valve can be removed from the mo...

Page 356: ...alve to adapter plate adapter plate from Hydraulic unit follow the procedure mentioned below 14 Disassemble PC DC operating links by removing the cotter pins from PC DC linkage assembly 17 Check the c...

Page 357: ...Charts Engine Differential Assembly Rear Axle Rear Axle Carrier and Brake Assembly Front Axle Differential Front Axle Side Section Speed Section Transmission Speed Section Transmission Range Section T...

Page 358: ......

Page 359: ......

Page 360: ...ntial Lock 10 Oil Seal 11 Pin Differential 12 Flange Bolt 13 Taper Roller Bearing 14 Retainer Differential Carrier 15 Bush Bull Pinion Shaft Support 16 Bolt 17 Washer Thrust Bevel Gear 18 Bevel Gear D...

Page 361: ...Retainer 3 Rear Axle Carrier 4 Collar 5 Bull Gear 6 Ball Bearing 7 Bull Pinion Shaft 8 Bearing Retainer 9 Bolt M8 x 20 10 Brake Assembly 11 Bearing 12 Oil Seal 13 Rear Axle 14 Nut 15 Spring Washer 16...

Page 362: ...ont 4 Thrust Washer 5 Differential Case 6 Thrust Washer 7 Bevel Pinion Differential 8 Bevel Gear Differential 9 Ring Gear 10 Shaft Beam Housing 11 Bearing Carrier 12 Housing Differential Carrier 13 Ta...

Page 363: ...Cover 8 Oil Seal 9 Swivel Housing 10 O Ring 11 Side Housing 12 Ball Bearing 13 Oil Seal 14 Collar 15 Retainer Washer 16 Spindle 17 O Ring 18 Hub Housing 19 Oil Seal 20 Ball Bearing 21 Straight Bevel G...

Page 364: ...ring 6208 13 Oil Seal 14 Spacer 15 Bush 4th Gear 16 Synchro Nizer 17 Fork 3rd 4th Speed 18 Gear 3rd Driven 19 Gear 2nd Driven 20 Bush 2nd 3rd 21 Fork 1st 2nd Speed 22 Gear 1st Driven 23 Bush 1st Gear...

Page 365: ...Speed Section Transmission Neutral Speed 1 Speed 3 Forward Engaged Speed 2 Speed 4 Reverse Engaged...

Page 366: ...put 15 Coupling 16 Bearing 6205 17 Bearing 6011 18 Gear Medium Driven 19 Sleeve 20 Splined Collar 21 Low Driven Gear 22 Bush Low Gear 23 Taper Roller Bearing 24 Spline Shaft 25 Ring Gear 26 Bearing 63...

Page 367: ...Range Section Transmission...

Page 368: ...Bracket CG 7 Engine Oil Level Check EO 8 Engine Oil Drain Plug EO 9 Engine Oil Filling Port EO 10 Trans Hydraulic Oil Level Check GO 11 Trans Hydraulic Oil Drain Plug GO 12 Trans Hydraulic Oil Filling...

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Summary of Contents for 35 Series

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Mahindra 35 Series, Service Manual

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Summary of Contents for 35 Series

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