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Mahindra 1635 Troubleshooting

The Mahindra 1635 compact utility tractor was manufactured between 2018 and 2023. The Mahindra 1635 tractor is powered by 4-cycle 3-cylinder direct injection naturally aspirated diesel engine. A 125 cubic inches (2 L) engine has a cylinder bore of 3.5" (89 mm), piston stroke of 4.33" (110 mm), and rated power of 36 hp (27 kW). The Mahindra 1635 is fitted with a 2 transmission options: 8x8 synchro shuttle transmission, or 3-range hydrostatic transmission. The maximum forward speed - 14.9 mph (23.8 km/h), maximum reverse speed - 12.2 mph (19.5 km/h).

 The open center hydraulic system includes a gear pump with rated fluid flow of 7.7 gal/min (29 l/min). The tractor is equipped with a hydrostatic power steering system, wet disc brakes, 28x8.5-15 front tyres, and 43x16-20 rear tyres. The wheelbase is 77 inches (1955 mm). The tractor is compatible with 72" mid-mount side discharge 3-blade Mahindra 1672M mower deck with cutting height of 1.0-4.0 in (25-102 mm), Mahindra 1635L front loader with maximum lift height of 87" (2200 mm), and Mahindra 1635B backhoe with maximum digging depth of 86" (2180 mm).

Engine Troubleshooting
Engine difficult to start or doesn't start

Air in the fuel pipes - Bleed the fuel pipes.
Dirty fuel filter - Filter maintenance required.
Fuel injection nozzles are faulty or clogged - Clean or replace injection nozzles.
Water in the fuel system - Change fuel and repair fuel system.
Incorrect valve clearance - Have it adjusted.
Fuel injection pump damage - Repair or replace injection pump.

Diesel starts but immediately shuts off

Plugged air filter - Carry out maintenance on air filter.
Fuel filter element is clogged - Install new filter element.
Poor fuel injection pump tightness - Look for any leaks of fuel pump Tighten it fast.
Fuel injectors are faulty or clogged - Replace or clean fuel injectors.
Fuel injection pump damage - Change pump or rebuild it.

Engine stalls during operation

Low coolant temperature - Warm up to required temperature.
Fuel filter element clogging - Replace filter element.
Air trapped in fuel system - Bleed air.
Fuel injection nozzles fault - Clean or change injection nozzles.
Improper fuel injection timing - Set up as recommended.

Engine stalls when idle

Incorrect low idle setting - Adjust the low idle speed.
Fuel injection pump malfunctioning - Rebuild or install a new injection pump.
Fuel injectors are faulty or clogged - Replace fuel injectors.
Valve clearance is not correct - Check and adjust.

Engine is not running at maximum power

Clogged air filter - Change air filter element.
Fuel injection nozzles fault - If necessary, replace with a new nozzle.
Insufficient fuel injection pressure - Repair or replace injection pump.
Excessive valve clearance - Adjust valve clearance according to specifications.
Incorrect low idle speed adjustment - Need to adjust idle speed.
Dirt in the fuel lines or hoses - Clean fuel hoses and lines.
Leaking cylinder head gasket - Install new cylinder head gasket.
Piston rings are worn or damaged - Replace piston rings.

Engine overheating

Insufficient coolant - Top up coolant fluid and check system for leaks.
Low engine oil level - Check and refill engine oil.
Dirty radiator fins or defective radiator cap - Install new cap or clean radiator.
Excessive wear of the fan belt - Fan belt must be replaced.
Engine overload - Reduce load or shift to lower gear.

Low oil pressure

Oil level is insufficient - Need to add oil.
Engine oil filter is plugged - Clean or change engine oil filter.
Improper type of engine oil - Use the specified type of engine oil.
Incorrect oil clearance in main bearing - Replace bearings.
Defective oil pump - Replace as required.

Abnormal engine noise or knocking

Low engine oil level - Add oil to the engine crankcase.
Engine is cold - Normalize the temperature by warming up the engine.
Improper setting of fuel injection pump timing - Adjust the pump as required.
Low idle speed setting is incorrect - Correct low idle adjustment.
Defective fuel injectors - Clean fuel injectors or change it.
Faulty or misaligned connecting rod - Connecting rod must be aligned or replaced.
Scored or worn pistons - Replace the pistons as required.

Transmission Troubleshooting
Transmission fluid pressure is insufficient

Transmission oil level is low - Check transmission oil level and add oil as required.
Clogged transmission oil filter element (if fitted) - Clean or replace the transmission filter.
Defective relief valve - Replace relief valve.

Transmission is making noise

Insufficient transmission oil - Add oil to the transmission housing.
Transmission oil is dirty - Transmission oil change required.
Worn gears or incorrect backlash - Replace defective gears or set backlash properly.
Worn or cracked bearings - Faulty bearings should be changed.
Worn or damaged gear shift forks - Shift forks need to be changed.
Shaft splines are damaged or worn - Change the shaft.

Hard to shift gears

Worn or rusty gear shift linkage - Replace or lubricate the shift linkage.
Worn or damaged gear shift forks - Install new shift forks.
Gearshift mechanism is damaged - Replace or repair the mechanism.
Worn or improperly adjusted clutch - Clutch adjustment or replacement required.

External fluid leaks

Transmission oil level is exceeded - Correct the oil volume.
Damaged seals or gaskets - Install new components.

Hydrostatic Transmission Troubleshooting
Excessive HST transmission noise

Insufficient oil level or contaminated oil - Fill to required level or change the transmission oil.
Speed control linkage is worn or unadjusted - Adjust or change linkage.
Stuck relief valve - Change the valve.
Transmission is under excessive load - The load should be reduced.
Transmission components are damaged or worn - After disassembling and inspection, change defective components.

Loss of power

Lack of transmission oil supply - Check and refill the transmission oil.
Relief valve failure - Change the valve.
Speed control linkage is defective or unadjusted - Adjust or install new linkage.

Transmission oil over heats

Lack of transmission fluid - Check and refill the transmission fluid.
Transmission oil filter is dirty - Clean or replace the transmission filter.
Plugged or defective cooling components - Check all cooling components and clean or replace if required.
Transmission overload - The load should be reduced.

Transmission oil leakage

Worn seals or gaskets - Install new components.
Internal transmission housing pressure is too high - Repair or replace damaged components.
Plugged transmission fluid return tube - Service or replace return tube.

Hydraulic System Troubleshooting
Low hydraulic system pressure

Insufficient hydraulic oil - Fill the system to proper hydraulic oil level.
Hydraulic oil filter is clogged - Replace hydraulic filter element or service if necessary.
Hydraulic pump is defective - Repair or replace hydraulic fluid pump.
Not adjusted hydraulic control valve - Need to adjust.
Hydraulic cylinder not working - Repair or replace hydraulic cylinder.
Leaking hydraulic lines - Inspect hydraulic system for leaks and repair it.

Hydraulic system overheats

Main relief valve malfunctioning - Replace relief valve.
Hydraulic fluid type is incorrect - Pour the correct type of fluid.
Contaminated hydraulic oil - Change hydraulic oil.
Air in hydraulic system - Bleed air from hydraulic system.

Hitch not raising or hitch raises slowly

Excessive hitch loading - The load should be reduced.
Hydraulic fluid level low - Add fluid as required.
Clogged hydraulic oil filter element - Hydraulic filter maintenance required.
Hydraulic pump is defective - Repair or replace hydraulic oil pump.
Damaged main relief valve - Replace relief valve.
Damaged hydraulic control valve - Repair or replace hydraulic valve.
Hydraulic cylinder not working - Replace or repair hydraulic cylinder.
Disconnected or broken suction line - Change or connect properly.

Hitch cannot be dropped or dropping is too slow

Hydraulic spool valve is out of adjustment - Spool valve adjustment required.
Hydraulic cylinder is faulty - Repair or replace hydraulic cylinder.
Hitch is out of adjustment - Adjust the hitch.
Worn hitch rock shaft - Replace the shaft.

Hitch lower or lift is jerky

Air in hydraulic pipes - Bleed hydraulic pipes.
Hydraulic oil is contaminated - Fill up with fresh hydraulic oil.
Hydraulic pump is defective - Change or repair hydraulic fluid pump.
Defective hydraulic spool valve block - Install a new valve or repair it.
Hydraulic cylinder failure - Change or repair hydraulic cylinder.

Steering Troubleshooting
Excessive effort to steer

Damaged or incorrectly assembled steering column - Replace steering column or assemble correctly.
Air in the hydraulic steering system - Bleed the steering system.
Not adjusted toe-in - Adjust toe-in wheels.
Uneven tyre pressure - Inflate the tyres properly.
Steering pump failure - Repair or change steering pump.
Steering pump control valve is worn or stuck - Flush or change flow control valve.
Steering oil level is insufficient - Checking steering oil level and add it if necessary.

Excessive steering wheel free play

Steering column coupling or shaft is worn - Change defective component.
Steering pump failure - Install a new hydraulic steering pump.
Steering linkage parts are loose or worn - Check and replace as required.

Front wheels wander to right or left

Uneven tire pressure - Inflate the tires properly.
Incorrect toe-in - Adjust toe-in wheels.
Loose or worn steering linkage components - Check and change as required.
Defective or improperly adjusted front wheel bearings - Change or adjust bearings correctly.

Electrical Troubleshooting
Battery is not charging

Electrical cable connections are loose or corroded - Tighten or clean electrical wiring connections.
Electrical terminal connectors are defective - Terminal connectors need to be changed.
Battery failing - Battery change required.
Worn or loose belt - Adjust belt tension or change the belt.

Starter turns slow

Low battery output - Recharge the battery.
Battery is not holding charge - Battery needs service or replacement.
Disconnected cables or faulty battery terminals - Connect cables correctly or replace terminals.

Starter motor won't turn

Battery is discharged or worn - Battery needs to be recharged or replaced.
Wiring is improperly connected or disconnected - Check wiring and connect properly.
Battery voltage is low - Battery is drained, recharge it.
Starter motor failing - Starter needs to be replaced.



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