Mahindra 35 Series, Service Manual

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C-75 35 Series 4WD, Model - 3535, 4035, 4535 and 5035 SM June’08
Probable Cause Remedy
Engine Knocks
1. One or more cylinders misfiring - - - - - - - - - - - - Locate and correct cause. Disconnect the injection
lines at the valve housing one at a time and check
for rpm drop of each cylinder.
2. Loose connecting rod - - - - - - - - - - - - - - - - - - - - Tighten connecting rod.
3. Poor grade of fuel, or water in fuel - - - - - - - - - Use good grade of fuel and check for water in fuel.
4. Incorrect engine temperature - - - - - - - - - - - - - - Keep temperature in work range of heat indicator.
Check thermostat for proper operation.
5. Injection pump timing not correct - - - - - - - - - - Time the injection pump correct. Refer fuel injection
system manual.
Excessive Smoke
1. Air cleaner clogged - - - - - - - - - - - - - - - - - - - - - - Service air cleaner as described in the operator’s
manual.
2. Engine overloaded - - - - - - - - - - - - - - - - - - - - - - Reduce load.
3. Improper fuel - - - - - - - - - - - - - - - - - - - - - - - - - - Use good grade of fuel.
4. Defective injection nozzle - - - - - - - - - - - - - - - - - Install new injection nozzle.
5. Worn pistons, rings and sleeves - - - - - - - - - - - - Install new parts.
6. Incorrect valve adjustment - - - - - - - - - - - - - - - - Adjust valves properly.
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 Failure
1. Low oil level - - - - - - - - - - - - - - - - - - - - - - - - - - - Maintain proper oil level.
2. Lack of oil - - - - - - - - - - - - - - - - - - - - - - - - - - - - Maintain proper oil level.
3. Engine runs too hot - - - - - - - - - - - - - - - - - - - - - Keep engine at normal operating temperature.
4. Loose bearings - - - - - - - - - - - - - - - - - - - - - - - - - Install new bearings.
5. Use of improper lubricating oil - - - - - - - - - - - - - Use grade of oil specified in operator’s manual.
6. Foreign materials entering engine - - - - - - - - - - - Use clean oil containers when filling engine with oil
and see that there no leaks in the air cleaner or in
the air induction system.
7. Oil lines clogged - - - - - - - - - - - - - - - - - - - - - - - - Clean all oil passages.
8. Connecting rod bent - - - - - - - - - - - - - - - - - - - - Align rod or install new.
9. Crankshaft out of alignment - - - - - - - - - - - - - - - Install new crankshaft.
Valves Sticking
1. Valve springs weak - - - - - - - - - - - - - - - - - - - - - - Install new springs.
2. Valve springs broken - - - - - - - - - - - - - - - - - - - - Install new springs.
3. Gummy deposits from inferior fuel or oil - - - - - Clean and use proper fuel or oil.
4. Valve stems scored or carboned - - - - - - - - - - - - Clean if necessary, install new valves.
5. Insufficient clearance between valve
stem and guide - - - - - - - - - - - - - - - - - - - - - - - - Ream valve guides for proper clearance.
Trouble Shooting