Mahindra 3535 Service Manual Download

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G-3

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

TROUBLE

PROBABLE CAUSE

REMEDY

REF.

BATTERY

1. Short circuits.

1. Locate shorts and correct

cause.

2. Defective regulator.

2. Replace.

3. Alternator not charging.

3. Check as below.

1. Improper battery solution level.

1. Keep proper water

level/solution.

2. Regulator defective.

2. Replace if necessary.

3. Internal short.

3. Replace.

1. Battery discharge

1. Check as above

2. Battery positive cable

2. Replace or repair

disconnected or improperly
connected

3. Battery negative cable

3. Replace or repair

disconnected or improperly
connected

1. Battery defective

1. Recharge or replace

2. Alternator defective

2. Repair or replace

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. Replace Regulator.

2. Worn brushes.

2. Replace brushes.

3. Dirty or oxidized slip rings.

3. Clean slip rings.

4. Sticking brushes.

4. Clean assembly and ease

brushes with fine cut file.

5. Low brush tension.

5. Adjust or replace brush

spring.

6. Alternator windings burnt out.

6. Replace alternator.

7. Broken or defective wiring.

7. Check wiring and make

connections.

1. Internal short.

1. Inspect and repair

alternator.

2. Voltage regulator defective.

2. Replace regulator.

CHECKING ELECTRICAL TROUBLES

1. Battery

Discharging

2. Battery

Overheating

1. No Alternator

output

2. Alternator

output excessive

3. All electrical

load don’t
operate

4. Battery

discharged
too quickly

Electrical System

Summary of Contents for 3535

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

Page 2: ...t 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 TRACTOR Splitting of Tractor B1 B32 Clutch D1 D10 GROUP D CLUTCH GROUP E TRANSMISSION Transmission E3 E22 Rear Axle E23 E30 Differential E31 E44 Differential Lock System E45 E50 Rear PTO Cover E51 E...

Page 3: ...P 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 Section Speed Section Transmission Speed Section Transmission Range Section Transmission Range Section Transmission Lubrication Greasing Chart 35 Series ...

Page 4: ...ty 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 chisel or other tools that may cause chips to fly 2 Keep work area organized and clean Wipe up oil or spills of any kind Keep tools and parts off of the floor Eliminate the possibility of a fall which cou...

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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 hammer chisel or other tools that may cause chips to fly 2 Keep work area organized and clean Wipe up oil or spills of any kind Keep tools and parts off of the floor Eliminate the possibility of a fall ...

Page 9: ...the 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 required for assembly B 2 Pins Bushes Inspect for damage scoring and pitting check with mating parts for wear Replace if necessary B 3 Clevis Clevis Pins and Circlips Check with mating parts for wear ...

Page 10: ...cale 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 03 8 04 2 7 16 11 11 043 4 to 047 0 06 0 06 5 1 2 12 70 061 5 to 068 7 08 5 09 5 9 16 14 29 086 7 to 097 6 12 0 13 5 5 8 15 88 115 5 to 130 0 16 0 18 0 3 4 19 05 195 0 to 217 0 27 0 30 0 7 8 22 22 2...

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 Never use steel or copper wire in place of fuse CONNECTOR For connector with Lock push lock to separate In separating connector do not pull with harness Do not throw or drop electrical parts and wire ha...

Page 12: ...rce 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 operation and keeping an adequate stock of service parts The purpose of this Serviceman s Manual is to supplement information given in the Operator s Manual which is supplied with every tractor It is th...

Page 13: ...ction 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 best guarantee for trouble free and efficient performance Repairs as described in foregoing and following chapters can be prevented The term off season applies generally to the winter months when the...

Page 14: ...e 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 of wear on a ball bearing hold the inner race with your hand and spin the outer race The sound emitted by a good ball bearing is very weak and similar to that of finger tips gliding over glossy pape...

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 must face the direction from which a force is applied See fig After every overhaul or major repair the tractor should be given new coat of paint The importance of this should not be underrated as mo...

Page 16: ...uild 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 installing new rings or sleeves as rings will not seat during idle operation Start Prior to starting make sure that a all bearings are pre lubricated b the crankcase is filled with specified engine oil c the ...

Page 17: ...e 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 1 Check the colour of the Smoke 2 Check the brakes for proper operation CHECK POINTS Wheel Mounting nuts checking Never operate tractor with untightened rim wheel Check all bolts and nuts frequently...

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 IN adjustments have been made the tractor should be jacked up and the axle tilted to its maximum tilt position In this position the wheels should be turned to the full left hand lock and at this ang...

Page 19: ...rovided 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 pulley groove Ensure first cylinder piston at compression TDC 6 Set dial gauge to read zero at above match position 7 Rotate pump gradually to upward downward direction till dial gauge showing specifi...

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 play of pedal stroke A Ensure free play is within specified limits If free play is not within specified limits adjust brake linkage as shown below Free Play Distance 1 57 to 1 77 inch 40 to 45 mm 1 L...

Page 21: ...3 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 and anti freeze until the coolant level is just below the port 7 Fill with clean water and anti freeze up the upper line of surge tank 8 Install the radiator cap 1 securely 9 Start and operate the e...

Page 22: ...the 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 sealed container Do not use radiator clearing solution when anti freeze has been added to the cooling water Anti freeze contains an anti corrosive agent which will react with radiator cleaning agent formi...

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 Check O rings of fuel filter for any crack damage Smear oil on the new O ring before installation 4 Clean the adaptor with clean diesel from inlet and outlet Ensure no dirt foreign particles entangled in...

Page 24: ...days 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 tighten if required Every 50 Hrs Check Fan Belt Tension and adjust if necessary Every 200 Hrs Flush Cooling System Every 1000 Hrs ELECTRICAL SYSTEM Clean Battery Terminals Every 200 Hrs Check Starter Mo...

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: ...sembly 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 the hood Negative Positive 3 First remove the battery cable from its negative terminal then remove battery cable from positive terminal Remove the battery NOTE Always disconnect the negative terminal f...

Page 28: ...e 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 air cleaner 8 Remove air cleaner by removing it from bracketaries 9 Remove the radiator inlet and outlet hoses ...

Page 29: ...e 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 oil spillage 13 Remove the propeller shaft guards 14 Remove the propeller shaft bearing from support bracket ...

Page 30: ...Check 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 15 Drive out rear coupling roll pin by suitable punch 16 Remove the propeller shaft 17 Support the Engine by placing a Jack below Engine Oil sump 18 Support the semi chassis by using the crane 19 Rem...

Page 31: ...e 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 Hose from HSU to PTO solenoid valve d Pipe from Hydraulic pump to Auxiliary valve 7 Disconnect accelerator cables from engine 8 Disconnect front wiring harness Starter motor wiring harness 9 Disconnect...

Page 32: ...nut 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 the clutch brake Vertical linkage connections below front platform 18 Disconnect the F R cable from HSU mounting bracket 19 Remove the wiring harness from firewall clamps completely 20 Dismantle the F...

Page 33: ...f 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 PTO input shaft in the pilot bearing Align PTO damper and PTO input shaft splines Turn the flywheel and main shaft hollow shuttle section at the same time while pushing the Engine towards clutch hous...

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 Remove the LH RH fenders 7 Remove the LH RH lower link stabilizers of 3 point linkage 8 Remove the ROPS 9 Remove the lower link support brackets LH RH 10 Drain the oil completely from the transmissi...

Page 35: ...from 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 filter 17 Disconnect the brake linkages at brake actuating lever 18 Remove the seat from mounting channels with LH RH mounting channels ...

Page 36: ...xle 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 platform 22 Dismantle the rear platform 23 Dismantle the isolator mounting bracket from Rear Axle ...

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 the reverse sequence of Splitting for rejoining Splitting Between Transmission Rear Axle Assembly ...

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 eliminate protection for the operator in the event of a roll over C DAMAGE OF THE ROPS If the Tractor has rolled over or the ROPS has been damaged such as striking an overhead object during transpor...

Page 39: ...Fold 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 Operating Position 1 Remove quick lock pins B and headed pins C 2 Loosen the knob D 3 Turn to raise the rollbar A of ROPS 4 Install pins C and quick lock pins B 5 Tighten the knob D ...

Page 40: ...ing 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 any injury 5 Loosen bolts B nuts C from ROPS mounting from both rear axle carrier 6 Follow the reverse sequence of removal for refitment of ROPS ...

Page 41: ...rom 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 firm before attempting its removal Improper inadequate supporting holding the hood in place during its removal can cause injury 7 Follow the reverse sequence of removal for refitment Align the hood r...

Page 42: ...cable 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 firmly before attempting its removal The fender needs to be held in place with external support Improper inadequate supporting holding the fender in place during its removal can cause injury 7 Refit t...

Page 43: ...del 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 reverse sequence of removal ...

Page 44: ...s 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 side fender only remove rear wheel LH side A to access the fuel tank B Model wise fender mounting positions identified on figure 3 Drain the tank completely either through water trap or through fuel...

Page 45: ...od 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 Refitment of the Battery 1 Refit the removed parts in the reverse sequence of removal 2 Refit the Battery Negative cable only at the end of assembly ...

Page 46: ...irst 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 bolts A slide it forward and remove from the engine Refitment of the Starter Motor 1 Refit the removed parts in the reverse sequence of removal 2 Refit the Battery Negative cable only at the end of as...

Page 47: ...ight 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 Distributor ROUTINE MAINTENANCE ALTERNATOR GENERAL Keep the Alternator reasonably clean and ensure that ventilation slot or air space are clear and unobstructed check mounting bolts for tightness BELT 1 Ensure...

Page 48: ...e 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 bolt locking the adjustable brace b Move the Alternator away from the engine to increase belt tension or push it towards the engine to decrease the tension c When the required tension is obtained ret...

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 safety cartridge is provided within the boundaries of paper element This can filter particles upto 120µ and is of use only in case of any leakage or rupture of paper element Also paper element is remo...

Page 50: ...od 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 be replaced DO NOT attempt to clean Secondary Element If Secondary Element is replaced install new element immediately to prevent dust from entering air intake system 11 Replace Secondary Element J i...

Page 51: ...en 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 the inside of air cleaner housing unloader valve with a damp cloth e Ensure that dust unloader valve is facing downward With 30 Deg Vertical axis f Install Primary Element cover and shut bonnet F SE...

Page 52: ...ss 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 to PTO engaging switch 6 Take out the top bottom steering column covers 7 Disconnect wiring harness to switches in the scuttle 8 Loosen the scuttle bolts and take out the scuttle REFITMENT OF INSTRUME...

Page 53: ...Fast 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 central wiring harness and remove the wiring harness from the firewall clamps 13 Disconnect the power steering hoses of HSU to steering cylinder HSU to PTO Control Valve and Pump to HSU 14 Disconnect the c...

Page 54: ...t 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 the Hydraulic Suction Lines 3 Connect the Steering Lines and Hydraulics Pressure lines NOTE Hold adapters when tightening Hydraulics Steering lines to eliminate overtightening of adapters on pump 4 ...

Page 55: ...em 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 strainer B is located on RH side of rear housing and can be removed as follows 1 Remove suction filter of Hydraulic Transmission 2 Remove the Cover Plate B by unscrewing four bolts 3 Pull the suction strain...

Page 56: ...d 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 For new switch add remove shims so that the tractor starts in neutral position only 3 After ensuring startability in neutral position tighten all hardwares to complete the assembly NOTE Incase forwa...

Page 57: ...Cylinder 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 C68 Special Notes Trouble Shooting C69 C76 Cooling System C77 C86 Air Cleaner C87 C92 Fuel System C93 C111 ...

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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: ...ts Description 5035 4535 4035 3535 MANIFOLDS CYLINDER HEAD VALVES INLET VALVES Number of per cylinder 1 Stem diameter mm Ø8 695 Ø8 707 Head diameter mm Ø38 25 Ø38 50 Clearance in guide mm 0 051 0 025 Valve seat angle 45º 20 0 Tappet clearance mm 0 25 Inlet Hot Cold 0 30 Exhaust Hot Cold EXHAUST VALVES Number of valves per cylinder 1 Stem diameter mm Ø8 675 Ø8 687 Port diameter mm 26 06 Head diamet...

Page 62: ...all end bush dia mm Ø30 950 Ø30 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 mm Top 2 568 2 607 Middle 2 47 2 495 Bottom 3 97 3 995 Ring Gap mm Top 0 25 to 0 45 Middle 0 70 0 95 Bottom 0 25 0 50 PISTON Type Material Aluminium Alloy Graded gms Weight difference should not be more...

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 Initial length mm 44 5 Spring Initial load N 17 LBS 6 Opening pressure PSI 30 35 VALVE clearance in bore mm 0 127 0 0889 OIL PUMP Clearances Gears to housing mm 0 135 0 211 Gears to end plate mm 0 05 0 1 D...

Page 64: ...entre 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 66 Idler gear 46 Tandem pump gear Backlash between any pair of gear mm 0 23 0 132 Idler gear end clearance mm 0 127 0 254 Idler gear end float mm 0 127 0 254 CRANKSHAFT Material EN25FQ or EN29B Main j...

Page 65: ...19 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 Bracket on Front Cover To Crankcase Bolt G7 938x63 5 18 to 22 Alternator To Alternator Mounting Bracket on Front Cover M8x1 25x85mm 18 to 22 Alternator To Brace Bracket bolt M10x1 5x25mm 20 to 25 Altern...

Page 66: ...ocker 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 to 30 Injector Spill Pipe Banjo M6 4 to 6 Air Intake Manifold Mounting Bolt M8 x 1 25 x 45 18 to 22 Heater For Cold Start M22 x 1 5 18 to 22 Tube Oil Level Gauge 12 to 15 Exhaust Manifold Sub assembly...

Page 67: ...erwise 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 four bearings 14 Crankshaft pinion 33 teeth when installing be sure mark lines up with mark on camshaft gear 15 Crankshaft front oil seal when installing apply a mixture of heavy oil and graphite to ...

Page 68: ...ves 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 frame connecting the front axle semi chassis and clutch housing The engine block is the main body of the engine around which the engine is built It is a one piece casting and webs integral with it form ...

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: ...speed 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 cam ground and are fitted with two compression rings and one conformable oil control ring The have a cavity in the piston crown itself to make a combustion chamber The fully floating piston pins are ...

Page 71: ...s 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 of the weight off the front tires Unbolt the radius arm bracket fit from the clutch housing 13 Remove the front support securing cap screws from both sides Raise tractor engine until crank shaft pul...

Page 72: ...ack 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 jacks till they bear the load 24 Remove all connections to the engine with clutch housing and vertical loads as described earlier 25 Take care that the transmission drive shaft is withdrawn squarely f...

Page 73: ...he 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 for testing 5 Insert and tighten the attaching bolts NOTE To assist assembly two longer bolts may be used to guide and to draw the engine upto the clutch housing 6 Installation is now the reversal of ...

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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: ...s 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 rocker arm shaft assembly thermostat housing inlet exhaust manifolds are fitted on the cylinder head The crankcase filler cap mounted on front cover also serves as a breather to the cylinder head The b...

Page 78: ...V 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 e Lift of the valve rocker arm shaft and brackets f Lift out the push rods marking them so that they may be returned to their original positions 3b DISMANTLING Rocker Arm shaft a Remove circlip from...

Page 79: ...rocker 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 screws b Install the value rocker arm shaft assembly on the studs as shown in Fig 7 and install the nuts 1 3 finger tight c Install the bolt in the centre bracket then tighten the nuts to the correct torq...

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 thermostat housing 6 Remove the fuel injector pipes It is not advisable to disconnect them at the injector only They may become distorted 7 Remove the cylinder head bolts progressively in the reverse order to...

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 slightly smaller than the guide to prevent it jamming in the bore 4c CLEANING INSPECTION REPAIR a CLEANING 1 Wash all parts in a suitable solvent and blow dry with compressed air 2 Remove any old gasket m...

Page 82: ...3 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 Bracket 25 Pin 26 Lock 27 Cup 28 Spring 29 Washer 30 Set 31 Valve 32 Valve Manifolds Cylinder Head Valves ...

Page 83: ...e 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 crankcase for warpage if engine has been run with a blown head gasket Fig 13 Observe checking pattern fig 12 see Specification f Check the valve stems for bends wear pitting or mushrooming of the en...

Page 84: ...hould 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 ASSEMBLY a Coat the valve stems with clean engine oil and install them in their original position b Install the valve spring seat and valve seals c Install valve springs and retainer Using valve spr...

Page 85: ...rvice 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 Excessive carbon deposition on valve neck and valve stem indicates engine oil consumption due to excessive clearance between stem and valve guide 3 Discard valve springs if they have lost tension or...

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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: ...of 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 cylinder sleeve has been worn so that there is a ridge in the sleeve at the upper end of the piston travel this must be removed before the piston is withdrawn to prevent damage to the ring lands and ri...

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 take an oversize piston pin Refer the specifications for dimensions h Insert piston ring in bore and use a piston without ring to it square in the bore Check the ring gap Fig 7 i Repeat operation h with...

Page 91: ...on 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 either side of the expander The gaps in the flat rings must be at 1800 to each other Piston Rings Check piston ring gap using a feeler gauge NOTE To check piston ring gap the ring must be placed squa...

Page 92: ...or 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 bore Failure to position correctly will result in the bearing halves being out of line when the bearing cap bolts are torqued g Install the oil pump h Install the cylinder head 6 DISMANTLING Using a...

Page 93: ...L 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 para 2a b Using a suitable sleeve puller withdraw the cylinder sleeves fig 13 c Remove the sealing ring from the groove in the crankcase bore And discard it 2 INSPECTION AND REPAIR See fig 10 a With th...

Page 94: ...leeves 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 soap solution and press the sleeve into the crankcase bore NOTE Weights refer to complete connecting rods with bushing bearing cap and bolts but less securing wire and without bearing halves c Check f...

Page 95: ...he 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 the reading 5 Take a reading three or four points around the sleeve and use the average reading normally the top of sleeve will extend 0 076mm 0 18mm above the cylinder block surface 6 Mark each sleev...

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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 spring 17 4 and relief valve 16 4 and gasket 18 4 3 INSPECTION REPAIR Check the oil pressure regulating valve spring Check the oil pressure regulating valve and seat for wear pitting or corrosion Check ...

Page 100: ...astigauge 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 gauges If necessary the end plate can be ground flat using a sheet of crocus paper on a surface plate Assemble the end plate and re check the clearance i If no clearance exists insert one additional ga...

Page 101: ...he 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 and filter element must be changed after every 200 hours of engine operation b Service Schedule For new tractor and overhauled engine first service Oil filter replacement after 200 hrs It is highly det...

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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: ...d 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 FRONT COVER 1 Removal a Remove the fan belt and fan as detailed in cooling system b Remove the bolt 2 1 c Remove front side hydraulic pump mounting bolts pull hydraulic pump out somewhat and move sligh...

Page 106: ...ent 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 will clear front axle support Then roll out from axle support with front axle and tires b Remove the front cover c Remove the nut 1 2 then remove the injection pump gear 2 2 d Remove the idler gear sha...

Page 107: ...gear 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 revolution and note dial indicator reading Compare reading with specifications a Remove the valve rocker arm shaft assembly b Lift out the valve push rods and identify them so they can be installed in th...

Page 108: ...amshaft 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 clearance of 0 008 0 017 between the gear hub rear face and the thrust plate Ensure that the thrust plate is located against its abutment shoulder when checking this clearance Fig 5 5 INSTALLATION a I...

Page 109: ...ce 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 Examine the tappet for signs of wear c Do not attempt to straighten or repair the camshaft If any parts are suspect they must be replaced Note When the engine is in the upright position the tappet mus...

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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: ...ing 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 one position therefore finished bearing caps cannot be supplied individually for service due to the necessity for line reaming to fit the particular bore where it is intended to mate The crankshaft s...

Page 114: ...tempt 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 new ring gear to 400 5500 F and install it ensuring that it is hard against the shoulder on the flywheel The ring gear must be installed with the lead on the teeth towards the crankcase on diesel engi...

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 2 4 and bearing inserts and identify them if them if they are to be re used h Lift the crankshaft from cylinder block and remove the bearing inserts 2 INSPECTION AND REPAIR a Clean all parts in a su...

Page 116: ...eing 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 Clean the blueing off the crankshaft and bearings 3 Checking main bearing running clearance 4 Install the upper bearing halves 5 Place the crankshaft in position 6 Lay a length of plastigauge along ...

Page 117: ...314 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 CONCENTRIC WITHIN 0 004 T I R 7 These holes must be clean and free of chips and burrs after grinding Remove sharp edges 8 1 313 1 316 1 321 1 323 1 328 1 317 1 322 1 325 1 327 1 332 Permissible width ...

Page 118: ...if 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 correct torque by stages to ensure even seating on the gasket NOTE The bottom face of the retainer after assembly must align with the face of the crankcase within 0 020 10 Trim the rear oil seal retainer g...

Page 119: ...g 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 rod side clearance to specifications f Use jointing compound and fit a new horseshoe gasket to the rear face of the crankcase lining up the holes in the gasket with the bolt holes g Apply a light coat...

Page 120: ...tments 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 removed condition A Rotate Crankshaft till TDC mark on main drive pulley matches with the pointer on front cover B The 1st Cylinder Piston is now to TDC Position at compression C If FIP mounting Studs...

Page 121: ...e 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 FIP as depicted in Fig B M Set the Dial to ZERO N Move the Rotary FIP towards or away from the Engine along the FIP mounting Studs till the Dial reads 0 95 0 02 mm for 4035 3535 1 0 0 02 mm for 4535...

Page 122: ... the 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 these figures will disclose errors or show improvements To check the cylinder compression screw in a plug port adapter in place of the injector of the respective cylinder and connect with compressio...

Page 123: ...lubrication 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 to run in for another hour during which the engine is accelerated to full speed for short periods Closely observe the engine during the running in time and note any faults for later correction When t...

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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: ...sure 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 repairs If only one cylinder is low squirt some engine oil on top of the piston and recheck If the pressure goes up worn rings are indicated if it doesn t go up valve leakage is indicated d If c above did...

Page 128: ...ve 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 fuel Check fuel tank b Fuel oil filter clogged Replace filters c Fuel filter gaskets defective air being drawn into fuel Replace gaskets d Moisture in fuel tank Drain entire system and fuel filter Re...

Page 129: ...s 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 Insufficient coolant in cooling system Check level and add if necessary Check hose connections for leaks 3 Dirt trash on outside of Radiator Clean between the tube fins with air or water pressure 4 Cooli...

Page 130: ...lve 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 inspect and if necessary replace 9 Oil pan drain plug loose or worn Install new drain plug and gasket tighten plug 10 Overheating Refer to Engine Overheats on previous page 11 Excessive oil poured into c...

Page 131: ...ly 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 ...

Page 132: ...ners 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 pump 3 Air leaks on suction side of injection pump Tighten fuel lines Check for defective fuel filter case gaskets Low Engine RPM 1 Governor control linkage binding or damaged Repair and install new pa...

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

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Page 135: ...on 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 with 15 psi radiator cap Recommended change period 1 year or when ever the radiator water is drained 1 SPECIFICATIONS Capacity US Gallon 2 24 4DI 1 84 3DI Pump Type Centrifugal Direction of rotation vi...

Page 136: ...water 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 Water Jacket provides sufficient Cooling at maximum temperature Cooling Points The Coolant continues to flow through the Cylinder Head to the Thermostat The thermostat is located at the front of the ...

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 cable before disconnecting any electrical system d Unclip the main cable harness from the bottom of the radiator e Disconnect the head lamp and horn cables if fitted f Remove the bolts from the botto...

Page 138: ...fill 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 in the Market like Brand Name Core Guard or some other names a Remove the Radiator from the Tractor b Block Inlet and Outlet Pipes with suitable adapters Connected an air pressure hose to the inlet A...

Page 139: ...w 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 as possible e Remove the four capscrews which secure the fan to the pulley hub To remove these capscrews work from the right hand side of the machine and ensure that each capscrew is rotated up to the...

Page 140: ...tuds 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 Thermostat is closed preventing circulation of Coolant until it reaches operating temperature The thermostat is set to open at 82O C 180O F NOTE When the Thermostat fails in the open position the Engine runs...

Page 141: ...are 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 Radiator blocking the cores Sponginess leads to lining failure and eventual rupture of the Hose When installing new hoses particular attention should be paid to the connections If you want a first class j...

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 Defective Water Pump 8 Inspect water pump impeller shaft If necessary replace 9 Dirty Scad Coolant passages 9 Clean flush passages 10 Radiator Togged 10 Flush out radiator 11 Fan Roll Slippage 11 Check the ...

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

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Page 145: ...rown 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 cartridge provided within the boundaries of paper element This can filter particles upto 120µ and is of use only in case of any leakage or rupture of paper element and also paper element is removed fo...

Page 146: ...p 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 replaced install new element immediately to prevent dust from entering air intake system 11 Replace Secondary Element J if dirty or damaged Dust Unloader Cyclopack Primary Element Filter Safety Cart...

Page 147: ...e 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 cloth e Ensure that dust unloader valve is facing downward With 30 Deg Vertical axis f Install Primary Element cover and shut bonnet F SERVICE INSTRUCTIONS 1 Check functioning of auto unloader of the dus...

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 Serviced After servicing reset the clog indicator by pressing rubber cap As marked in the figure Ensure red band will move to the original position after resetting Air Cleaner Red Flap ...

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 The machine is fitted with a heat indicator the transmitter must be removed from the cylinder head Disconnect the tractor meter drive at the instrument panel 7 Turn the steering wheel to the full left...

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 Feed Pipe from tank to filter The Screw type Valve arid Seal Assembly has two positions off and on The fuel is allowed to flow while the valve is screwed out and vice versa Remove the fuel cock and b...

Page 153: ...r 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 operation 1 to expel and air which may have been drawn in 6 Turn the engine for one half revolution and repeat item 2 to ensure complete scavenging of transfer pump 7 Loosen the connections on the hig...

Page 154: ...llation 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 system For efficient combustion and optimum engine performance it is imperative that the injection nozzles are always in functionally satisfactory condition so that accurately metered quantities of fu...

Page 155: ...ncreased 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 Other contributory factors such as poor compression injection timing cooling problems exhaust intake restriction Lubrication systems problems operating conditions etc should also be investigated 6 Fuel f...

Page 156: ...emoval 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 nozzles into the cylinder head is completed nozzle protrusion of 1 7 to 2 3 mm is to be ensured The cross sectional view of the engine showing the nozzle tip protrusion is show in fig 6 Fuel System ...

Page 157: ...Injection 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 the scribed mark on the pump mounting flange is mid way between the marks on the crankcase front plate 2 Bleed the fuel system NOTE Calibration chart of Fuel injection Pump different models are give...

Page 158: ...in 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 gauge to read zero at above match position 5 Rotate pump gradually to upward downward direction till dial gauge showing specified reading Injection Timing mm tdc For 4035 3535 0 95 0 02 mm For 4535 50...

Page 159: ...ot 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 hand priming using filter ensure that the ignition key is OFF bleeder screw in filter is loose DO NOT attempt to prime the system with ignition key ON as it may impart additional resistance to filter ...

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: ...hragm 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 finger 0 11 inch 2 Release lever height from flywheel main drive 1 71 0 078 inch Pedal setting 1 Pedal freeplay 1 6 to 1 8 inch TORQUE 1 Clutch release fork bolt 41 50 Nm 30 37 lb ft 2 Clutch assy mount...

Page 171: ...bly 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 loosening bolts A and separate clutch assembly 3 Remove main clutch plate B 4 Fit the clutch assembly F and tighten mounting bolts and remove guide shaft tool C ...

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 spliting the tractor between clutch housing and engine refer the procedure as detailed in Spliting The Tractor 3 Punch the mark matching clutch cover and flywheel position to ensure that the clutch is i...

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 the burrs entering into the assembly 2 Remove 1 0 mm material from pressure plate face final finishing cut and then verify at H pointing If all the check points are OK then use cover assy as it is 6...

Page 174: ...nywhere 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 to prevent the burrs entering into the assembly Remove 1 0 mm material from pressure plate face and it can be removed in the three phase two rough cut and one final finishing cut and then verify belo...

Page 175: ...sembly 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 of drive strap together and insert it to the pressure plate rivet as shown 4 By using alignment screw screw it into the ring as shown Fig 9 This is mainly to avoid dislocation all straps The above pr...

Page 176: ...n 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 in the pilot bearing of the flywheel will aid installation of the clutch NOTE The end of a transmission shaft will serve for the single clutch or a special tool is available See special tool list 2 Li...

Page 177: ...ansmission 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 1 Steering Mechanism 1 Refer to Steering Faulty Mechanism Section 2 Brake Pedals Interlocked 2 Release Pedal Lock 3 Differential Faulty 3 Remove disassemble and inspect D Tractor moves but turns 1 B...

Page 178: ...l 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 E58 Brakes E59 E65 ...

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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: ...ow 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 Spacer shuttle option spacer 2 Between speed top shaft rear bearing 0 004 0 008 Graded Bush speed bearing front 1st Gear 3 Between speed countershaft rear 0 004 0 008 Graded Shim bearing circlip 4 Bet...

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 Transmission Case Flange Bolt M10 x 25L 41 50 14 Retainer Rear Axle Carrier M10 x 35L 41 50 15 Carrier Differential Case LH To Bolt M12 x 1 25 x 30L 92 113 Transmission Case 16 Rear Cover To Bearing Retaine...

Page 184: ...rk 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 Magnetic Drain Plug 1 2 14 NPTF 70 77 38 Breather Clutch Housing 1 2 14 NPTF 70 77 39 Lock Nut Counter Shaft M24 x 2 110 120 40 VTU Mounting Bolt M10 x 1 5 x 110 41 50 41 VTU Mounting Stud M10 x 60 57 77 ...

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 Synchronizer unit defective Repair or Replace Clutch does not release Adjust Wrong grade of oil Change 5 Differential Lock Differential lock shifter fork damaged Replace can not be set Differential lock shifter...

Page 186: ...d 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 Forward Gear Driven F Reverse Gear Driven ...

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 Reverse Idler Gear I flows to Counter Shaft Reverse Gear F and then to Synchroniser D to Counter Shaft J Major Components A Transmission Drive Shaft B PTO Drive Shaft C Speed Driving Shaft D Forward 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 M to 1st Driven Gear O on Speed Shaft Shifting Ring engaged with 2nd Gear The power flows from Counter Shaft J 2nd Gear Driving N to 2nd Driven Gear P on Speed Shaft C to the Synchronizer L splined ...

Page 189: ...hifter 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 Range Shaft Q through coupling K Shifter ring engaged with 4th gear The power flows from Counter Shaft J 4th Gear Driving T to 4th Driven Gear V on Speed Shaft C to the Synchronizer R splined with the ...

Page 190: ...s 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 Shaft All range driven gears are free to rotate in the neutral condition on shaft pinion Shift Coupling Engaged with high gear The power from Range Shaft high driving gear A flows to high driven gear B...

Page 191: ...ng 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 the spline shaft D Shift Coupling Engaged with Low gear The power from Range Shaft low driving gear H flows to low driven gear I through Coupling C to the spline shaft D RANGE GEAR SECTION ...

Page 192: ...Remove 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 Remove front retainer D 7 Remove PTO input shaft remove transmission driving hollow shaft along with front bearing Hold the gears and spacers in position Remove gears and spacers 8 Remove top cover E by ...

Page 193: ...everse 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 pin L by using special tool 13 Remove speed rail detention bolt springs and balls remove forks and rails 14 Remove middle wall ball bearing by removing circlip top shaft ...

Page 194: ...r 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 countershaft towards rear Try to rotate countershaft for ease of dismantling Remove shaft and forward Reverse gears Synchro assembly and speed driving gears 3 nos and splined bushes B Cleaning and Inspection...

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 then put bushes gears and Synchro 6 Front bearing to be push on Speed Top Shaft and check float as required To adjust float use graded 1st gear bush 7 Install front and rear circlip 8 Assemble shuttle ...

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 special tool slot and fork hole then insert ball and spring 5 Rotate special tool to ensure locking of ball and spring 6 Slide rail slowly towards rear keeping fork assembly in position with tool 7 Lock th...

Page 197: ...4 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 rear PTO cover assembly along with wet clutch assembly and 540 input shaft and gear assembly 6 Remove external circlip inside hub and remove hub 7 Remove PTO middle support bearing rear circlip 8 Re...

Page 198: ...tap 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 Slide rail from rear side 2 Insert fork in coupling and lock with spring pin with rail 3 Insert ball spring at front and rear position of transmission case and insert retention bolt and torque with ...

Page 199: ...Remove 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 Take lever close to wall 9 Remove fork with ball and spring fitting fork position as per requirement to avoid flying of spring and ball 10 Remove oil seal and circlip from 4WD output shaft 11 Tap the o...

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

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Page 202: ...tial 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 21 Retainer Oil Seal 22 Rear Axle Carrier 23 Taper Roller Bearing 24 Bull Pinion Brake Shaft RH 25 Brake Assembly RH 26 Gasket Brake Cover 27 Brake Pin 28 Bearing Retainer Bull Shaft 29 Carrier Diffe...

Page 203: ...he 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 wheel to be wedged 2 Use proper jack under the clutch housing or transmission case 3 Remove tires 4 Disconnect the wiring harness from couplers 5 Remove ROPS by removing ROPS Mounting Bracket Assembl...

Page 204: ...sling 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 washers as shown in fig 2 Remove bull gear B 3 Tap the rear axle splined end with copper hammer and pull out the rear axle from other end Rear Axle ...

Page 205: ...e 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 Inspect gear for worn chipped or broken teeth Check splines for burrs and correct fitting 4 Check bull pinion shaft for damage pitting and burrs and backlash 5 Check Ball Bearings and oil seals for dama...

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 Install outer ball bearing with fixture for positioning of bearing 5 Apply liquid gasket on retainer ...

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 Reverse procedure of removal using liquid gasket and tighten the mounting bolts as specified b Check the gap between rear axle face and bull gear face by dial gauge add required shims to fill up the...

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

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Page 210: ...ation 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 differential pinion to rotate on it s own axis and they roll over bevel gear and thus producing differential action DIFFERENTIAL LAYOUT 1 Spline Shaft 2 Pinion Differential Case 3 Differential Case ...

Page 211: ...d 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 The differential gear assembly is a mechanism to provide smooth steering It automatically provides relative speed to both rear wheels according to road resistance and braking friction at the wheel L...

Page 212: ...e 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 Axle Carrier g Remove retainer A alongwith differential housing assembly by loosening bolt B h Tap slightly o take out the differential assembly C complete NOTE Remove differential lock shifting arran...

Page 213: ...hould 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 poppet recesses and freedom of movements grooves for damage f Replace all not serviceable parts with new NOTE Use new oil seals O ring and poppet springs 5 Dismantling of Differential Assembly a Place the...

Page 214: ...ow 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 Check bevel gear and thrust washer surface of both bevel gears worn or damaged Replace the parts d Check the ring gear for wear and damage If no longer serviceable replace it with spiral pinion shaft...

Page 215: ...e 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 Assembly to Transmission a Install differential assembly in transmission case from LH side cutout and hold b Install RH side bearing cup in Transmission case c Locate differential assembly in RH side c...

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 cone with spline shaft 2 Insert spline shaft from transmission case rear side 3 Insert all gear bearing spacers Spline collar as shown in section For correct preloading use graded spacer between front ...

Page 217: ...s 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 figure and pull NOTE 1 Pull to keep the assembly revolving at constant speed which should be between 4 4 6 6 lbs 2 Preloading the differential case and spline shaft should be done before assembling of...

Page 218: ...hery 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 width from the small end Adjusting with thicker shims to move spline shaft backward and place the RH shim to left to move ring gear left ward Repeat above until proper tooth contact and backlash are ac...

Page 219: ...he 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 pre load on the spline shaft rear bearings is the equivalent of 0 005 tight the thickness of spacer and shims is determined as in the following example End float measured 0 003 Fixed pre load 0 005 Th...

Page 220: ...cone 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 shaft mounting distance is directly etched on the bevel gear machined face as 0 636 or any 2 Install the spline shaft using a shim pack of 0 090 between the bearing cone and the Transmission case 3 Us...

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 Bull Gear 10 Bull Pinion Brake Shaft RH 11 Rear Axle 12 Differential Housing Assembly ...

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

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Page 224: ...pling 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 pinion shaft rotate with equal RPM DIFFERENTIAL LOCK DISENGAGED POSITION DIFFERENTIAL LOCK ENGAGED POSITION Differential Lock System EXPLODED VIEW OF DIFFERENTIAL LOCK PEDAL LINKAGES A Oil Seal B Differen...

Page 225: ...edure 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 differential lock fork and pull differential cross shaft from RH side Removal of Differential Lock Shaft Pin Removal of Differential Lock Shaft Special Tool ...

Page 226: ...e 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 and spring dowel at LH side 4 Installation a Installation is reverse procedure of Removal Oil Seal Fitment Assemble Diff Lock Shaft Assembling Differential Lock Shaft Assembly with Fork ...

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

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Page 230: ...sembly 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 clutch d Then clamp the mounting bolts to the specified torque values A REAR PTO COVER 1 DISMANTLING a Loosen bolt A of rear PTO cover B b Loosen bolt C of plate retainer D NOTE Hydraulic Housing on ...

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

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Page 234: ...spline 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 output shaft bearing and oil seal in cover assembly output shaft b Hold the Output gear in position with input gear c Push output shaft in out put gear with spacer in position and insert in bearing an...

Page 235: ...irclip 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 with the bearing retainer e Assemble the complete rear cover assembly along with clutch and gear into transmission case with the help of longer stud NOTE Ensure that the brake lug of wet clutch is pr...

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

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Page 238: ...actuating 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 disc worn Replace Actuating plate warped Replace Brake lever and shaft damaged Replace Transmission oil improper Change 4 Brake Noisy Wrong grad oil Change Contaminated oil with water Change A TROUBLE S...

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 Brake liners get compressed between Cover Plate and Rear Axle Carrier Housing Friction Plate get compressed between adjacent mating surface so frictional force is generated and this force stops the rotat...

Page 240: ...anical 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 approx Several tens of micron depending on the accuracy of parts during the initial contact in the initial period of 50 hrs or 80 hrs Almost no wear occurs afterwards This means that very little wear adj...

Page 241: ...bench 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 bolts G e Take out bull shaft H with bearing I by slight tapping Brakes Removal of Cover Plate Brake Removal of Brake Plates Removal of Bull Pinion Brake Shaft ...

Page 242: ...aged 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 dismantling and installation procedure are same with other side brakes 5 Installation a Reverse procedure of removal and dismantling b Tighten the bolts at specified torque and check all friction plates a...

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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 ...

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Page 246: ...e 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 with bevel gears provides wider steering angle and greater durability B Maintenance Points C Lubrication Greasing Grades Application Range 1 Oil Drain Plug Swivel Housing LH 2 Oil Filling and Level ...

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 weight distribution Remove excessive weight and redistribute load following instructions related to the vehicle 3 Different rotation radius of the tires If one tire has a smaller radius it will cause...

Page 248: ...ion 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 accident 3 Load bump 1 Insufficient lubrication 2 Contaminated oil 3 Excessive use 4 Normal wear out 5 Pinion nut loosened Replace bevel gear set Follow carefully the recommended operations for the adjustme...

Page 249: ...components 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 Vehicle intensively operated or overloaded 1 Wheel support loosened 2 Beam body bent Replace the gasket or seal and matching surface if damaged Use correct lubrication and replace at recommended intervals...

Page 250: ...e 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 increasing the speed 3 Pinion or input flange worn out 3 Adjust 1 Ring gear damaged 1 Replace bevel gear set 2 Differential box bolts loosened 2 Tighten to torque 1 Ring gear teeth or pinion damaged 1 Replace...

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 Axle Spacer Hex Bolt 1 2 20 UNF x 120 100 110 To Side Housing For 33 To 43 PTO 13 Beam Housing To Front Axle Spacer Hex Bolt 1 2 20 UNF x 35 100 110 To Side Housing For 29 PTO 14 Cover Swivel Housin...

Page 252: ...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 contact point with Micro meter or Vernier caliper If the measured value is less than usable limit replace the pillow block Front Rear Standard Values as ø 70 ø 74 assembled mm Usable limit mm ø 70 2 ø 74 2 ...

Page 253: ...ISMANTLING 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 reduction bevel gear to separate 3 Separate hub housing bearing by removing retainer and spacer and pressing from spindle end remove bearing NOTE Inspect bearing and oil seal O ring for damage if required r...

Page 254: ...e 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 PINION GROUP DISMANTLING Place the housing input shaft on fixture and lock the pinion Unscrew the locknut with special spanner provided NOTE This is the destructive operation for the lock nut Remove the l...

Page 255: ...eal 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 housing 6 Place a spindle axle F on fixture and put O ring G on the flange 5 ASSEMBLY OF FRONT AXLE A HUB HOUSING ASSEMBLY ...

Page 256: ...fully 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 bolt head 11 Fit O ring K in place NOTE Apply oil to O ring before fitment Front Axle A HUB HOUSING ASSEMBLY ...

Page 257: ...ing temperature 120ºC 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 Fit the allen bolt G with copper washer NOTE During oil filling in swivel housing remove the allen bolt and fit after oil filling Front Axle ...

Page 258: ...bearing 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 special nut C Adjust nut till desired backlash and crimp D the special nut 4 Check the backlash it should be between 0 13 to 0 20 mm 5 Fit the oil seal E ...

Page 259: ...ut 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 inside swivel housing 4 Fit the cover D on swivel housing and tighten bolts E to torque 65 72 Nm 5 Check backlash for final reduction gear pair it should be between 0 13 to 0 30 mm if necessary adjust the...

Page 260: ...LY 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 mounting bolt to specified torque 70 80 Nm and tighten the nut to torque 110 Nm ...

Page 261: ...ASSEMBLY 1 Insert bearing A on spiral bevel pinion B NOTE Temperature of bearing 120ºC 2 Place the housing input shaft C on a flat surface 3 Press the outer cone of bearing to both side of housing input shaft 4 Put shims D and spacer E on pinion 5 Insert housing input shaft to the pinion ...

Page 262: ...en 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 to avoid damage to O ring Press oil seal Then tighten lock nut to 65 Nm and measure preload Finally crimp the lock washer in pinion slot provided Preload after oil seal fitment to be 4 to 5 Kg NOTE ...

Page 263: ...e 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 with proper dolly 5 Assemble differential case LH G along with thrust washer H and differential gear I 6 Assemble differential case LH and RH with position mark as supplied Front Axle ...

Page 264: ...he bolts with washer by bending it on bolt head 10 Fit the taper roller bearing K temp 120ºC on LH differential case 11 Fit the cone L into bearing carrier M with taper roller bearing N NOTE The taper roller bearings and cups cones are not serviceable separately Ensure to assemble new match pair while repairing 12 Hold the housing differential carrier O on suitable fixture and place differential a...

Page 265: ...the 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 the bolts to 120 Nm torque 16 Check the differential gear backlash as specified Backlash Differential gear 0 1 to 0 25 mm Adjust the backlash by shifting shims Q from one side to other Front Axle ...

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 housing C in differential 5 Put spacer D to beam housing both end side Not Applicable for 29 PTO NOTE This spacer is not applicable for 29 PTO tractors 6 Fit side housing to beam housing with the help...

Page 267: ...guard 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 torque 160 Nm Pillow Block Bolt Adjustment 1 Assemble the Pillow Blcok front and rear with semichassis with the help of bolts 2 Fix the semichassis and try to swing the axle 3 Then tighten pillow bloc...

Page 268: ...ng 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 Front Axle Spacer 29 O Ring 30 Top Cover RH 31 O Ring 32 Side Housing RH 33 Dowel 34 O Ring 35 Shim 36 Hub Housing 37 Bevel Gear Final 38 Straight Bevel Gear 39 Cover Swivel Housing Bottom 40 Swivel ...

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 ...

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Page 271: ...ace 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 Replace Regulator 2 Worn brushes 2 Replace brushes 3 Dirty or oxidized slip rings 3 Clean slip rings 4 Sticking brushes 4 Clean assembly and ease brushes with fine cut file 5 Low brush tension 5 Adjust or ...

Page 272: ...egulator 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 If the bulb now lights the 1 Replace Regulator cause is faulty regulator If the bulb does not lights ground A terminal of the Alternator 2 If the bulb lights now brush lead the causes are a Jammed b...

Page 273: ...tive 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 defective Safety 4 Replace interlock not working a P T O Relay PTO flahser a Check if it is not ok replace b Neutral switch b Check and replace if not OK 5 Internal damage to starter 5 Repair or replace mot...

Page 274: ...e 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 improperly connected between panel board and engine oil pressure switch 1 Key switch defective Replace 2 Wiring harness short Repair or Replace 1 Fuel solenoid defective Replace 2 Key switch defectiv...

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 Replace 2 4 WD Sensor switch defective Replace 3 Wiring harness disconnected Repair or Replace 4 Cluster defective Investigate Repair or Replace 1 Fuse blown Replace 2 Brake switch defective Pork Replace ...

Page 276: ...proper 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 disconnected Repair or Replace Between main switch terminal and hazard unit Between hazard unit and hazard switch terminal and hazard light 4 Hazard switch defective Replace 5 Flasher defective Replace...

Page 277: ...lace 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 Wiring faulty Rectify or Replace 7 Plow lamp Electrical System 8 Fuse blown frequently 9 Heater Indicator continuously ON NOTE If heater indicator is ON for more than 2 minutes switch OFF the tractor and ...

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 assembly The panel is secured by four screws on the scuttle assembly under the steering wheel The operator can easily pay attention on the gauges and indicators and can reach to the switches and control...

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 The Fuel Gauge indicates quantity of fuel available in the fuel tank Refill the fuel tank when the pointer lies in Red Band Coolant Temperature Gauge This gauge indicates coolant temperature of the e...

Page 280: ...It 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 is running this indicator should go OFF if the Battery is getting charged If the indicator glows continuously even when the engine is running above low idle rpm of the engine The cause should be inve...

Page 281: ...tch 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 the combination switch in LH side of steering column on dashboard ON position operates LH RH turn signal lamps simultaneously This operation can be performed even if the key switch is in OFF position ...

Page 282: ...minate 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 2 Left Operates LH Turn signal Lamp 3 Right Operates RH Turn Signal Lamp Starter Key Switch It is a key operated 3 positions rotary switch It is located in RH side of steering column on dashboard It...

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 Engage Disengage Switch is in ON position When this switch is in AUTO POSITION the PTO shaft rotation will be stopped as soon as the implement is raised This will happen irrespective of clutch being engag...

Page 284: ...he 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 Engage Disengage Switch the operator has a CHOICE to select AUTO or MANUAL MODE through PTO Mode Switch The PTO will turn Off if the PTO Engage Disengage Switch or PTO Mode Switch is in OFF position Refe...

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 Rear Brake Lamp LH 5 Turn Signal Lamp RH 6 Reflector Rear Position Lamp RH 7 Rear Brake Lamp RH 4 Lamps ...

Page 286: ...e 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 and push up in the direction of arrow marked on the cover c The fuse is located at LH side behind clutch pedal Press plastic cover of the fuse box from top and bottom The fuse cover will come out If ...

Page 287: ...d 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 both plates is converted into lead sulphate robbing the acid of its sulphur 3 BATTERY REMOVAL a Open the hood b Remove the battery cable from its negative terminal and then positive terminal c Remov...

Page 288: ...ed 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 contacts close connecting the starter to the battery directly this bye passes the series winding also called as operating winding of the solenoid Shunt winding also called hold on winding which is ener...

Page 289: ...ommet 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 Seal End Cover 29 C Washer 30 Earth Terminal 31 Spring End Cover 32 C E Bracket Assembly 33 Brush Set 34 Brush Carrier Assembly 35 Lead Assembly 36 Grommet 37 Field Coil Assembly 38 Armature Assembly...

Page 290: ...winding 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 terminal on the solenoid phenolic moulded terminal base and ground When the switch is closed both pull in and hold on windings get energised resulting in pulling in of plunger At the end of the travel the m...

Page 291: ...jelly 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 fuel flow 2 Ensure fuel flow does not fire 3 Remove the Starter Motor 3 Check the starter if found check defective replace the starter motor C Starter works 1 Pinion sticky on shaft 1 Replace starter m...

Page 292: ...Voltage 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 SPECIFICATIONS FOR ALTERNATOR 1 Type 3GA15 2 Rating Continuous 3 Normal Output 12 V 4 Weight 7 Kg Approx Incl Pump Pulley 5 Rated Max Output Speed 6000 R p m 6 Max Permissible Speed 11 500 R P M 7 Po...

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 should read 14 1 14 6 Volts 10 Disconnect the Air pipe at the Vacuum pump install Vacuum gauge Run Alternator at 5 000 RPM speed After 35 seconds the Vacuum reading should read 500 mm Hg 11 Close th...

Page 294: ...LT 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 REMOVE THE ALTERNATOR AND CHECK CONNECT DC AMMETER IN SERIES WITH ALTERNATOR BATTERY POSITIVE TERMINAL ENSURE THAT THE AMMETER READING FALLS BETWEEN 7 TO 10 AMPS IN CASE THE BATTERY IS FULLY CHARGED T...

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 Dust Cap 48 Delivery Connector Assy 49 Sealing Washer 50 Screw 51 Oil Inlet Plug 8 EXPLODED VIEW ALTERNATOR 18 Insulating Washer 19 SRE Bracket Assembly 20 Brush Set 21 Regulator Brush Box Assy 22 In...

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 ...

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Page 299: ...ch3 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 ø 63 mm 2 48 in 3 Rod ø 38 mm 1 50 in 4 Stroke 220 mm 8 66 in d Filteration Strainer 100 mesh and suction line filter 10 micron common with hitch circuit e Maximum Operating Temperature 90oC Steering ...

Page 300: ...TTINGS 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 HSU 6 Cylinder Power Steering 7 Hose HSU To Cylinder 8 Hose Pressure HSU Integral Column 9 Hose ...

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 connector of HSU to separate HSU In case any internal leakages observed remove HSU unit to replace O Rings seal kit as follows Hydraulics Steering Unit Removal Ref Fig 1 Loosen the cap screws of unit 2...

Page 302: ...d 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 Random sampling should be taken from hydraulic systems on vehicles ready to ship to ensure cleanliness level meets ISO 18 13 or better Exposed Surfaces Exposed cylinder rods should be handled with ca...

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

Page 304: ...e 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 manual pump attached to and driven by the steering wheel develops the necessary pressure The initial effort to turn the steering wheel in either direction instantly increases hydraulic pressure in the m...

Page 305: ...goes 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 steering cylinder The fluid from the engine driven pump enters the control valve and this fluid passes through the control valve spool passage into the manual pump The fluid the passes through and out of...

Page 306: ...replacement 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 Hydraulic Suction Lines 3 Connect the Steering Lines and Hydraulics Pressure lines NOTE Hold adapters when tightening Hydraulics Steering lines to eliminate overtightening of adapters on pump 4 Connect ...

Page 307: ...eed 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 Maintain correct inflation pressure in front tire Always use a puller to remove the steering wheel Do not use a hammer torch or crow bar Investigate and correct immediately any play raffle shimmy or...

Page 308: ...opeller 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 axle steering cylinder p Remove Steering cylinder mounting bolts from axle q Move away the steering cylinder 9 Inspection Visually inspect all parts and replace those parts which are not in good con...

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 approximately six seconds e With the engine running at rated speed and tractor standing on dry concrete input torque should not exceed 3 8 Nm f Stop the engine and using the special spanner and a spring balanc...

Page 310: ...ntervals 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 these investigations bring no result proceed to inspect the tandem pump manual steering control unit manual pump and or steering cylinder refer to general information in respective section and follows ...

Page 311: ...nder 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 Remove wear or damaged seals or o rings and install with new one If these seals or O Rings damaged this will result into external leakages Steering ...

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 cylinder housing face mounting bolt 2 Tighten the allen screw of cylinder head to cylinder housing as per the specified torque i e 25Nm 18 lb ft NOTE Whenever dismantling of steering cylinder for inspection...

Page 313: ...valve 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 steering problems can be corrected if the problem is properly defined The entire steering system should be evaluated before removing any components The steering control unit is generally not the cause o...

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 Leaking relief valve Repair or replace the accessory in cylinder lines valve Piston seal blown out Determine cause Correct and replace seal Loose steering wheel nut Tighten the nut Steering column shaft wo...

Page 315: ...300 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 steering control unit Large particles in meter section Clean the unit Insufficient hydraulic power Check hydraulic power supply units over 15 in3 Severe wear and or broken pin Replace the unit Thermal s...

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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 ...

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Page 319: ...res 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 Loader Valve TECHNICAL FEATURES Operation with draft and position control Reading of traction force on top link Adjustment of operating sensibility during draft control work Lowering speed adjustment of ...

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 Power Steering Cylinder 10 PTO Control Valve 11 PTO Wet Clutch ...

Page 321: ...ctors 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 hydraulics and Brakes A strainer is fitted on transmission Addition paper filter is incorporated on suction line which ensure 100 filteration Lift housing houses lift cylinder control valve shockloa...

Page 322: ...through 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 the regulator piston 2 to open the holes 17 and the oil flows to the tank The oil contained in the cylinder 23 remains under pressure by means of the check valve 3 by the discharge valve 4 and by the...

Page 323: ...flows 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 annular duct 18 and feeds chamber 23 of the cylinder The regulator piston 2 regulates the oil flow of the cylinder because chambers 15 and 22 are subject to the difference in pressure created by 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 valve 8 and hole 24 enters in the discharge valve 4 flowing to the tank from hole 25 causing the lowering of the arms In this phase the lowering speed of the arms can be regulated by the manual lever...

Page 325: ...lywheel 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 be lifted During the lifting movement of the arms crank 13 with pin 10 will rotate in an anti clockwise direction and by means of the link 14 will cause position cam 6 to rotate clockwise When the ro...

Page 326: ...nsion 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 outward by its spring Moving the draft control lever 2 toward backstop E the leverage system will function in the following manner The crank 15 being an integral part of the draft shaft 16 rotates cou...

Page 327: ...ion 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 previously established by position control lever 1 flywheel 7 roller 4 and position cam 6 the distributor shaft 21 is prevented from entering the lowering position S and therefore the arms cannot sink even th...

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 the ground till reaching the desired depth by gradually moving the lever 2 down The implement depth reached is proportional to the draft determined by soil hardness In this condition the rockshaft k...

Page 329: ...ill 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 uniform work when coming up against a less hard ground For raising and having the implement penetrated at the end and beginning of each pass acting on position lever 1 only It is not correct to find t...

Page 330: ...STMENT 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 creates a pressure in the cylinder of 50 60 bar Loosen the fastening screw 6 so as to free the position control lever 1 from the shaft 5 With the draft control lever 2 at its lowest position against...

Page 331: ...ry 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 fixed and with lever 1 against the backstop F keep the lever fixed with the shaft by tightening fully the fastening screw 6 To control raise completely the arms by moving the position control lever 1 ag...

Page 332: ...must 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 minimum RPM slowly raise the draft control lever 2 The adjustment of the draft lever 2 is correct when it is moved upward and this allows the arms to be completely raised NOTE The position of the lev...

Page 333: ...al 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 assemble the push rod in the same position Ensure also that the measurement of the spring is 55 0 0 2 mm The control of the measurement of the push rod with respect to the control valve face is carried o...

Page 334: ...aulics 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 Compensator Linkages Cap Screw 88 98 Nm 65 72 Lb ft 9 TORQUE DETAILS ...

Page 335: ...35 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 Screw 68 88 Nm 50 65 Lb ft 9 TORQUE DETAILS Contd ...

Page 336: ...35 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 Screw 19 29 Nm 14 21 Lb ft 9 TORQUE DETAILS Contd ...

Page 337: ...not 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 lever travel Sensibility adjusted badly Adjust sensitivity of Control Valve The rockshaft does not Discharge Valve blocked Remove Control Valve and descend unblock or clean discharge valve Lifting capa...

Page 338: ...m 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 the Control the implement drops Valve is badly adjusted Control Valve too much or doesn t stay in the groove The draft control does not Draft control lever is Adjust the draft control lever function 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 lock pedal 5 Remove four wheel lever plate 6 Remove fender to front platform bolts 7 Remove ROPS connecting plate bolt 8 Remove wiring connections and dismantle 9 Remove gear lever rubber boot and knob...

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 bolt to 41 50 Nm 30 37 lbs ft 18 Connect lift unit supply line Tighten to torque to 60 Nm 45 lbs ft assembly Hydraulics 19 Install top link and connect lift links 20 Follow the reverse sequence of dis...

Page 341: ...LL 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 socket head screw A two cap screw B lever position control C and hub D 4 Loosen set screw E in link F ...

Page 342: ...of 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 shaft and apply multipurpose grease on shaft 12 Install support over shaft and tighten two screw 13 Install new O ring on lever draft control 14 Install lever draft control into support 15 Install snap r...

Page 343: ...er 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 from lift unit 4 Loosen bolts D of bracket lubrication E and take it out 5 Remove snap ring F G 6 Loosen pin H I and take out cam compensator assembly and linkages ...

Page 344: ...ts 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 necessary 11 Reverse the dismantling procedure for assembly and installation NOTE Apply thread sealant to allen set screws during assembly 12 Adjust hydraulic lift unit position and draft sensing feedbac...

Page 345: ...ockshaft 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 recommended grade and quantity 9 Adjust hydraulic control valve Service Recommendation It is not recommended to repair Flow Control Valve Flow Control Valve should be completely replaced if internal proble...

Page 346: ...ven 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 from opposite side of control levers on hydraulic NOTE Index parts to hydraulic with a punch mark before disassembly to aid in correct alignment of these parts during assembly Slightly tap lift arms t...

Page 347: ...ushing 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 spring pin 13 Install crank assembly into housing and connect to feedback linkages with lock washer 14 Install shaft through housing and crank aligning indexing marks from disassembly 15 Clean threads of...

Page 348: ...ontrol 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 Insert a long wood dowel or brass drift through cylinder opening to remove piston F 7 Inspect all part for wear or damage Check piston and cylinder for cracks or scoring Replace as necessary Always us...

Page 349: ...aulics 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 sealant to threads of allen set screws 12 Install hydraulic lift unit ...

Page 350: ...parate 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 top link bracket for any wear or damage 4 To remove top link bracket assembly completely 5 Remove lock roll pin G of pin H to take ...

Page 351: ...er 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 to the spring J 8 Install top link bracket assembly to hydraulic 9 Apply grease on spring before fitment ...

Page 352: ...ASSEMBLY 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 repair Relief Valve assembly Relief Valve assembly should be completely replaced if internal problem suspected ...

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 Wet PTO Clutch synchroniser and spline shaft Now when it is put to ON position solenoid gets energised and shifts the spool This diverts part of oil to the PTO clutch cylinder and hence PTO gets engag...

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 cotter pin E and washer F 5 Loosen the small nut G behind the clevis H and take out clevis from inner cable Preserve the clevis safely 6 Loosen nuts I on cable outer and remove cable assembly from bracke...

Page 355: ...o 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 mounting bracket for replacement by removing mounting bolts NOTE Do not fit repaired auxiliary valve on the tractor It is recommended to replace the complete auxiliary valve with cable assembly as a si...

Page 356: ...valve 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 condition of the O Rings on the adapter plate for damages and replace with new ones if required NOTE O Rings from closing flange assembly mounted on hydraulic lift housing has been used for adapter pl...

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 Transmission Range Section Transmission Lubrication Greasing Chart 35 Series ...

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Page 360: ...ential 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 Differential LH 19 Carrier Differential LH 20 Bolt 21 Lock Plate Differential Case 22 Gear Crown Wheel 23 Washer Thrust Bowl Pinion 24 Shaft Differential Pinion 25 Pinion Differential 26 Bevel Gear Di...

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 Brake Lever 17 Oil Seal 18 Brake Cover 19 Brake Cam 20 Spring 21 Steel Ball 22 Brake Plate 23 Brake Disc 24 Steel Plate 25 Brake Pin ...

Page 362: ...ront 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 Taper Roller Bearing 14 Shaft Differential Pinion 15 Spiral Bevel Pinion 16 Housing Input Shaft 17 Pillow Block Rear ...

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 Gear 22 Bearing 23 Shaft Side Housing 24 Straight Bevel Pinion 25 Bevel Gear Intermediate Reduction 26 Bevel Pinion Intermediate Reduction 27 Cover Swivel Housing 28 Ball Bearing ...

Page 364: ...aring 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 Graded 24 Bearing 6307 25 Main Top Shaft Speed Section 26 Coupling Speed Range 27 Coupling Speed PTO 28 Breather 29 Bearing 6405 30 Bush Forward Reverse 31 Gear Reverse Driven 32 Forward Reverse Sync...

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

Page 366: ...tput 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 6307 27 Shaft PTO Output 28 Gear Rear PTO 29 Bearing 6307 30 Oil Seal 31 Rear Cover 32 Bracket PT Shield Mounting 33 PTFE Seal 34 Bearing 6306 35 Shaft PTO Input 36 Wet Clutch 37 O Ring 38 Hub PTO Clut...

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 Port GO 13 Front Axle Oil Level Check FO 14 Front Axle Oil Drain Plug FO 15 Front Axle Oil Filling Port FO 16 Quadrant Linkages Shaft Hyd CG No D e s c r i p t i o n Lubricant ...

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Mahindra 3535, Service Manual

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