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Mahindra 3535 Troubleshooting

The Mahindra 3535 compact utility tractor was manufactured between 2009 and 2018. The Mahindra 3535 tractor is powered by Mahindra CE-35 3-cylinder direct injection water-cooled diesel engine. A 115.4 cubic inches (1.9 L) engine has a cylinder bore of 3.5" (89 mm), piston stroke of 4.0" (102 mm), and rated power of 35 hp (26 kW). The Mahindra 3535 is fitted with a two transmission options: 12x12 full synchromesh transmission, or three-range hydrostatic transmission.

The maximum forward speed - 15.3 mph (24.5 km/h), maximum reverse speed - 14.4 mph (23 km/h). The open center hydraulic system includes a gear pump with rated fluid flow of 11 gal/min (41.6 l/min). The main relief pressure is 203 bar (2950 psi). 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 71 inches (1800 mm). The tractor is compatible with Mahindra ML120 front end-loader with a maximum lift height of 106" (2690 mm), and Mahindra 485 backhoe with maximum digging depth of 101" (2555 mm).

Engine Troubleshooting
Engine difficult to start or doesn't start

There is air in the fuel system - Bleed the system.
Clogged fuel filter - Install new filter element.
Fuel injection nozzles are damaged or dirty - Install a new kit of correctly balanced nozzles.
Water in the fuel system - Change fuel and repair fuel system.
The valve clearance is not adjusted - Adjustment procedure required.
Fuel injection pump malfunctioning - Repair or replace injection pump.

Engine starts but stalls immediately

Air filter element clogged - Clean or replace the element.
Fuel filter element is dirty - Change the filter element.
Fuel injection pump leakage - Check the fuel injection pump for leaks and fix it.
Dirty or defective injectors - Inspect fuel injectors and change as required.
Fuel injection pump malfunctioning - Repair or install new pump.

Diesel shuts off while driving

Coolant temperature is low - Warm up to required temperature.
Fuel filter element clogging - Service the filter.
Air in the fuel system - Air bleeding.
Defective injection nozzle - Install a new kit of correctly balanced nozzles.
Improper fuel injection timing - Set the fuel pump timing correctly.

Engine stops while idle

Incorrect low idle setting - Correct low idle settings.
Fuel injection pump is faulty - Install a new pump or rebuild.
Fuel injector fault - Replace fuel injectors.
Excessive valve clearance - Have it adjusted.

Reduced engine power

Air filter clogged - Replace air filter element.
Clogged or burnt injection nozzle - Install a new kit of correctly balanced nozzles.
Improper fuel injection pressure - Correct the pressure settings.
The valve clearance is incorrect - Check and adjust as required.
Incorrect low idle speed adjustment - Adjust the low idle speed.
Fuel hoses or lines are clogged - Clean fuel hoses and lines.
Damaged cylinder-head gasket - Install new cylinder head gasket.
Piston rings are worn or damaged - Change piston rings.

Engine overheating

Low engine coolant - Top up coolant fluid and check system for leaks.
Engine oil level is insufficient - Check and refill engine oil.
Damaged radiator cap or dirty radiator core - Replace cap or clean radiator.
Fan belt is broken or worn - Replace as required.
Engine overload - Reduce engine load.

Insufficient oil pressure

Low crankcase oil level - Add oil to the engine crankcase.
Oil filter element is dirty - Change or clean engine oil filter element.
Oil grade or viscosity is wrong - Drain crankcase and refill with correct oil.
Incorrect oil clearance in main bearing - Bearings need to be reinstalled.
Oil pump is defective - Inspect and change as required.

Engine noise or knocking

Engine oil level low - Check and refill engine oil.
Engine not warmed up - Warm up to required temperature.
Improper setting of fuel injection pump timing - Adjust as recommended.
Low idle speed adjustment is incorrect - Adjustment required.
Defective fuel injectors - Inspect fuel injectors and change as required.
Connecting rod is misaligned or defective - Need to align or replace the connecting rod.
Worn or scored pistons - Install new pistons.

Transmission Troubleshooting
Low transmission oil pressure

Insufficient transmission oil - Add oil to the transmission housing.
Clogged transmission oil filter element (if fitted) - Service or change transmission oil filter.
Stuck relief valve - Change relief valve.

Transmission makes excessive noise

Insufficient transmission oil - Check transmission oil level and add oil as required.
Transmission fluid contamination - Change the fluid.
Backlash is incorrect or gears are damaged - Adjust backlash correctly or replace the gears.
Bearings are damaged or worn - Replace faulty bearings.
Worn or bent shift forks - Change the shift forks.
Worn or damaged shaft splines - Replace the shaft.

Hard to shift gears

Rusty or worn gear shift linkage - Install a new gear shift linkage.
Damaged or worn gear shift forks - Shift forks need to be changed.
Worn parts of the gear shifting mechanism - Change worn parts.
Worn or improperly adjusted clutch - Adjust or replace the clutch.

Transmission fluid leaks

High transmission oil level - Correct the oil level.
Damaged seals or gaskets - Gaskets or seal need to be replaced.

Hydrostatic Transmission Troubleshooting
Excessive HST transmission noise

Insufficient oil level or contaminated oil - Add oil to proper level or pour fresh transmission oil.
Speed control linkage is worn or unadjusted - Replace or adjust linkage.
Relief valve malfunction - Replace relief valve.
Transmission overloaded - Reduce loading.
Damaged or worn components of hydrostatic transmission - Change or repair defective parts.

Loss of power

Transmission oil level is low - Fill the transmission housing with oil.
Relief valve is damaged - Replace valve as required.
Bent or unadjusted speed control pedal linkage - Adjust or change linkage.

Transmission fluid over heats

Lack of transmission oil supply - Fill the transmission housing to proper oil level.
Dirty transmission oil filter element - Service or replace the transmission oil filter.
Damaged or clogged cooling components - Check all cooling components and change or repair if required.
Transmission is under excessive load - The load should be reduced.

External fluid leaks

Worn seals or gaskets - Install new seal or gaskets.
High internal transmission case pressure - Repair or replace damaged components.
Clogged oil return pipe - Clean or change return pipe.

Hydraulics Troubleshooting
Hydraulic fluid pressure is low

Low hydraulic oil level - Fill the system to proper hydraulic oil level.
Clogged hydraulic oil filter element - Clean or change hydraulic filter.
Hydraulic pump malfunction - Install a new hydraulic oil pump.
Hydraulic control valve block is out of adjustment - Control valve needs to be adjusted.
Hydraulic cylinder malfunction - Repair or install a new hydraulic cylinder.
Leaking hydraulic lines - Find leaks in the system and fix it.

Hydraulic system overheats

Main relief valve is faulty - Relief valve must be changed.
Improper hydraulic oil type - The proper type of hydraulic oil must be used.
Contaminated hydraulic oil - Change hydraulic oil.
Air in hydraulic lines - Bleed hydraulic lines.

3-point hitch can't lift or lifts too slowly

Excessive hitch loading - The load should be reduced.
Low hydraulic fluid level - Add fluid as required.
Clogged hydraulic oil filter element - Service the hydraulic filter or change if required.
Hydraulic pump failure - Change or repair hydraulic fluid pump.
Faulty main relief valve - Change relief valve.
Defective hydraulic control valve block - Repair or replace hydraulic valve.
Defective hydraulic cylinder - Replace or repair hydraulic cylinder.
Suction line is loose or broken - Replace or repair.

3-point hitch won't lower or lowers slowly

Incorrect adjusted hydraulic spool valve - Adjust the spool valve correctly.
Broken hydraulic cylinder - Repair or install a new hydraulic cylinder.
Unadjusted hitch - Adjust as required.
Hitch rock shaft is worn Change the shaft.

Hitch jerks when drop or lift

Air in the hydraulic system - Air bleeding.
Hydraulic fluid is dirty - Hydraulic fluid change required.
Defective hydraulic pump - Repair or replace hydraulic fluid pump.
Defective hydraulic spool valve block - Install a new hydraulic valve or repair it.
Hydraulic cylinder is defective - Repair or replace hydraulic cylinder.

Steering System Troubleshooting
Steering wheel is difficult to turn

Incorrectly fitted or worn steering column - Refit or replace the steering column.
Air lock in hydraulic steering system - Need to bleed air.
Improper toe-in - Check toe-in and correct.
Front tyres wear unevenly - Change the tyres.
Worn steering pump - Repair or replace steering pump.
Stuck or damaged steering pump control valve - Change or flush control valve.
Steering fluid level low - Checking steering fluid level and add it if necessary.

Excessive steering wheel play

Worn steering column coupling or shaft - Replace defective part.
Steering pump malfunction - Install a new steering pump.
Worn or loose steering linkage joints - Inspect and replace as required.

Front wheels wander to left or right

Front tyres wear unevenly - Change the tyres.
Improper toe-in - Check toe-in and correct.
Steering linkage components are loose or worn - Repair or change steering linkage.
Defective or improperly adjusted front wheel bearings - Adjust properly or replace bearings.

Electrical Troubleshooting
Battery does not charge

Electrical cable connections are loose or corroded - Clean or tighten connections.
Faulty battery terminal clamps - Replace terminal clamps.
Defective battery - Change the battery.
Defective or loose belt - Adjust belt tension or install a new belt.

Starter motor cranks slow

Low battery power - Charge the battery.
Battery drains quickly - Service charging system or install new battery.
Battery terminals are corroded or wires are disconnected - Check wiring and clean or replace terminals.

Starter doesn't crank

Battery is discharged or defective - Need to charge or replace the battery.
Wire harness is disconnected or incorrectly connected - Check wire harness and connect as required.
Battery capacity is low - Battery is drained, charge it.
Faulty starter motor - Change or repair starter.



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