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Mahindra 3540 Troubleshooting
The
Mahindra 3540 is a four-wheel drive utility tractor from 3500 Series. This model
was manufactured from 2015 to 2019. The Mahindra 3540 tractor is powered by
166.7 cu.in (2.7 L) 4-cycle 4-cylinder direct injection naturally aspirated
water-cooled diesel engine with a rated power of 40 hp (29.8 kW). The Mahindra
3540 is fitted with a two transmission options: power shuttle transmission with
12 forward and 12 reverse gears, or 3-range hydrostatic transmission with
infinite forward and reverse gears.
The maximum travel speed (forward/reverse): 15.3 mph (24.5 km/h) and 14.4 mph (23 km/h). The open center hydraulic system has a gear pump with a rated capacity of 11 gpm (41.6 lpm). The hydraulic system pressure is 200 bar (2900 psi). The tractors are equipped with 9.50x16 or 29x12.50-15 front tires and 14.9x24 or 44x18-20 rear tires. Compatible attachments for the tractor: Mahindra 3550L front end-loader with a maximum lift height of 111.5" (2830 mm), and Mahindra 50B backhoe with maximum digging depth of 115" (2920 mm).
| Diesel Engine Troubleshooting |
| Engine hard to start or doesn't start |
Air in the fuel system - Air bleeding.
Fuel filter plugging - Clean or change the filter.
Dirty or faulty injection nozzles - Change fuel injection nozzles.
Dirt or water in fuel system - Drain water or flush dirt from the system.
Improper valve clearance - Adjust valve clearance.
Fuel injection pump malfunction - Rebuild or replace pump.
| Engine starts but then stalls |
Air filter plugged - Change air filter element.
Fuel filter element is dirty - Service the filter.
Problems with fuel injection pump tightness - Inspect fuel injection pump for leaks.
Fuel injectors are faulty or clogged - Change or clean fuel injectors.
Faulty fuel injection pump - Replace or repair injection pump.
| Engine shuts off suddenly while running |
Coolant temperature is low - Warm up the engine.
Fuel filter plugging - Install new filter element.
Air in the fuel pipes - Bleed the fuel pipes.
Fuel injection nozzles are faulty or clogged - Test injection nozzles and change if necessary.
Timing of fuel injection pump is incorrect - Set the fuel pump timing correctly.
| Engine stalls at low idle speed |
Incorrect low idle speed adjustment - Correct low idle settings.
Defective fuel injection pump - Rebuild or change fuel pump.
Defective fuel injectors - Clean or replace fuel injectors.
Valve clearance is not correct - Adjust valve clearance.
| Engine is not running at maximum power |
Restricted intake air - Clean or replace element.
Faulty or dirty injection nozzles - If necessary, replace with a new nozzle.
Insufficient fuel injection pressure - Test fuel injection pressure and adjust it correctly.
Improper valve clearance - Correct valve clearance.
Low idle speed setting is incorrect - Correct low idle settings.
Fuel hoses or lines are dirty - Fuel hoses and lines must be clean.
Damaged cylinder-head gasket - Replace cylinder head gasket.
Leaking or damaged piston rings - Replace the piston rings as required.
| Engine is overheated |
Lack of engine coolant - Add coolant fluid and inspect the cooling system for leaks.
Low engine oil level - Fill up the engine oil.
Dirty radiator core or faulty radiator cap - Clean radiator or replace cap.
Fan belt is broken or worn - Replace as required.
Engine is running overloaded - Reduce load or shift to lower gear.
| Oil pressure too low |
Lack of oil - Add oil as required.
Oil filter is clogged - Service or replace engine oil filter.
Oil grade or viscosity is wrong - Fill up with the correct oil viscosity.
Crankshaft bearing oil clearance is excessive - Bearing replacement required.
Defective oil pump - Remove and inspect oil pump.
| Engine knocking sound or abnormal noise |
Low engine oil level - Check and refill engine oil.
Low coolant temperature - 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 - Adjust low idle speed.
Clogged or defective injectors - Clean or replace fuel injectors.
Connecting rod failure or misalignment - Replace or align connecting rod.
Broken or worn pistons - Pistons replacement required.
| Transmission Troubleshooting |
| Insufficient transmission fluid pressure |
Lack of transmission fluid - Check and refill the transmission fluid.
Clogged transmission oil filter element (if fitted) - Service or replace the transmission oil filter.
Relief valve is damaged - Change the valve.
| Transmission makes noise |
Lack of transmission oil supply - Fill the transmission housing with oil.
Transmission fluid is contaminated - Change the fluid.
Gears are damaged or backlash is incorrect - Replace gears or adjust backlash correctly.
Worn or cracked bearings - Bearings replacement required.
Worn or damaged gear shift forks - Shift forks need to be replaced.
Worn or stuck shaft splines - Change the shaft.
| Gear shift is hard |
Gear shift linkage is rusty or worn - Lubricate or replace the shift linkage.
Worn or bent gear shift forks - Shift forks need to be changed.
Worn out parts of the gearshift mechanism - Replace worn parts.
Clutch is out of adjustment or defective - Adjust clutch or replace if required.
| Transmission fluid leaking |
Transmission fluid level is exceeded - Excess fluid must be drained.
Worn seals or gaskets - Change defective gaskets or seal.
| Hydrostatic Transmission Troubleshooting |
| Hydrostatic transmission noise |
Contaminated transmission fluid or low fluid level - Top up to proper level or change transmission fluid.
Defective or not adjusted speed control pedal linkage - Replace or adjust linkage.
Relief valve failure - Replace relief valve.
Excessive transmission load - Reduce loading.
Transmission components are damaged or worn - Replace or repair defective components.
| Low power |
Transmission oil insufficient - Need to add transmission oil.
Relief valve is damaged - Install a new relief valve.
Speed control pedal linkage is bent or not adjusted - Adjust or change linkage.
| Transmission oil overheating |
Lack of transmission oil supply - Fill up the transmission oil.
Clogged transmission fluid filter - Service or replace the transmission fluid filter.
Damaged or clogged cooling components - Check all cooling components and clean or replace if required.
Transmission overloaded - Reduce the load is required.
| Transmission oil leaking |
Seals or gaskets are worn - Install new gaskets or seal.
Transmission case internal pressure is too high - Repair or replace damaged components.
Clogged oil return pipe - Clean or change return pipe.
| Hydraulics Troubleshooting |
| Low hydraulic system pressure |
Hydraulic oil level low - Need to add oil.
Dirty hydraulic fluid filter element - Clean or change hydraulic filter.
Faulty hydraulic pump - Install a new hydraulic oil pump.
Hydraulic control valve is set improperly - The control valve must be set correctly.
Hydraulic cylinder is broken - Replace or repair hydraulic cylinder.
Leaks in hydraulic pipes - Check the hydraulic system and fix leaks.
| Hydraulic system is too hot |
Main relief valve malfunction - Replace relief valve.
Improper type of hydraulic oil - Use the proper type of oil.
Dirty hydraulic oil - The oil must be changed.
Air in hydraulic lines - Bleed hydraulic lines.
| Hitch not raising or hitch raises slowly |
Excessive load on hitch - Reduce the load is required.
Hydraulic fluid level low - Fill the system to proper hydraulic fluid level.
Clogged hydraulic oil filter - Service or replace the hydraulic filter.
Defective hydraulic pump - Replace or repair hydraulic oil pump.
Main relief valve failure - Relief valve must be changed.
Hydraulic control valve block is defective - Repair or change the valve.
Faulty hydraulic cylinder - Replace or repair hydraulic cylinder.
Suction pipe is disconnected or broken - Connect or replace pipe.
| 3-point hitch cannot be lowered or lowering is too slowly |
Hydraulic control valve is not set properly - Adjust properly.
Hydraulic cylinder is faulty - Change or repair hydraulic cylinder.
Three-point hitch has not been adjusted - The hitch must be adjusted.
Damaged lift arm shaft - Replace the shaft.
| 3-point hitch jerks when lower or lift |
Air in hydraulic lines - Bleed hydraulic lines.
Hydraulic fluid is contaminated - Fill up with new hydraulic fluid.
Hydraulic pump malfunction - Change or repair hydraulic fluid pump.
Defective hydraulic spool valve - Install a new hydraulic valve or repair it.
Hydraulic cylinder is defective - Repair or install a new hydraulic cylinder.
| Steering System Troubleshooting |
| Steering wheel turns hard |
Defective or incorrectly mounted steering column - Change steering column or mount correctly.
Air lock in hydraulic steering system - Bleed the steering system.
Improper toe-in - Adjust toe-in wheels.
Tires have uneven wear - Replace the tires.
Hydraulic steering pump is defective - Check the steering pump and replace if necessary.
Stuck or damaged steering pump control valve - Install a new flow control valve or clean it.
Not enough steering oil - Check oil level and add steering oil as required.
| Excessive steering wheel free play |
Steering column coupling or shaft is extremely worn out - Replace faulty part.
Defective hydraulic steering pump - Steering pump needs to be repaired or replaced.
Loose or worn steering linkage components - Repair or change steering linkage.
| Tractor is pulling to right or left |
Tire pressure is uneven - Adjust the tire pressure.
Not adjusted toe-in - Adjust toe-in wheels.
Steering linkage parts are loose or worn - Check and change as required.
Defective or improperly adjusted front wheel bearings - Adjust correctly or install new bearings.
| Electrical Troubleshooting |
| Battery does not charge |
Corroded or loose cable connections - Tighten or clean electrical wiring connections.
Battery terminal connectors are defective - Install new terminal connectors.
Defective battery - Replace the battery.
Loose or worn belt - Replace belt or adjust belt tension.
| Starter turns slowly |
Battery power is low - Battery is drained, charge it.
Battery is not holding charge - Service charging system or replace battery.
Wires are disconnected or battery terminals are corroded - Connect cables correctly or replace terminals.
| Starter is not cranking |
Battery is drained or defective - Battery needs to be recharged or replaced.
Wire harness is disconnected or incorrectly connected - Check wire harness and connect as required.
Low battery output - Charge the battery.
Starter motor is defective - Starter should be replaced.
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