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Mahindra 4035 Troubleshooting

The 4-wheel drive Mahindra 4035 compact utility tractor was manufactured between 2009 and 2020. The Mahindra 4035 tractor is powered by CE-40 four-cycle three-cylinder direct injection naturally aspirated 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 40 hp (29.8 kW). The Mahindra 4035 is fitted with a 2 transmission options: 12x12 synchro shuttle transmission, or 3-range hydrostatic transmission.

The maximum forward speed - 16.5 mph (26.6 km/h), maximum reverse speed - 15.6 mph (25.1 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, 9.50x16 (AG) or 12.0x16.5 (Industrial) front tyres, and 14.9x24 (AG) or 16.9x24 (Industrial) rear tyres. The tractor is compatible with KWM ML120 front end-loader with a maximum lift height of 106" (2690 mm), and Bradco 485 backhoe with maximum digging depth of 101" (2555 mm).

Engine Troubleshooting
Engine difficult to start or won't start

Air in fuel tank - Bleed fuel tank.
Dirty fuel filter - Service or replace the filter.
Fuel injection nozzles are clogged or faulty - If necessary, replace with a new nozzle.
Water or dirt in fuel system - Drain, flush, and service the system.
Improper valve clearance - Adjustment procedure required.
Fuel injection pump is broken - Rebuild or install a new injection pump.

Diesel starts and stops

Air filter clogged - Clean or change the filter.
Fuel filter plugging - Change filter element.
Fuel injection pump has loose connections - Tighten the connections.
Fuel injectors are faulty or clogged - Inspect fuel injectors and change as required.
Fuel injection pump is damaged - Change or repair the pump.

Engine shuts off while running

Engine is not warmed up to the required temperature - Warm up the engine.
Dirty fuel filter - Service the filter.
Air trapped in fuel system - Bleed air.
Dirty or damaged injection nozzles - Check injection nozzles and replace if required.
Wrong setting of fuel injection pump timing - Adjust according to specifications.

Engine stops while idle

Low idle speed setting is incorrect - Test and adjust.
Fuel injection pump failure - Repair or install new pump.
Fuel injector fault - Replace fuel injectors.
Incorrect valve clearance - Adjustment procedure required.

Engine power is reduced

Restricted intake air - Clean air cleaner element.
Fuel injection nozzles fault - Clean or change injection nozzles.
Fuel injection pressure is wrong - Adjust to proper pressure.
Valve clearance is out of adjustment - Adjust valve clearance.
Improperly adjusted low idle speed - Correct low idle settings.
Dirty fuel lines or hoses - Clean fuel system hoses and lines.
Damaged cylinder-head gasket - Gasket should be replaced.
Damaged or leaking piston rings - Replace the piston rings as required.

Engine overheated

Engine has a lack of coolant - Top up coolant fluid and check system for leaks.
Engine oil insufficient - Fill up the oil to required level.
Dirty radiator fins or defective radiator cap - Replace cap or clean radiator.
Broken or loose fan belt - Belt replacement is recommended.
Engine is running overloaded - Reduce engine load.

Oil pressure is insufficient

Oil level is low - Fill up the engine oil.
Clogged oil filter - Replace or clean engine oil filter element.
Incorrect engine oil Use the specified type of engine oil.
Incorrect oil clearance in crankshaft bearing - Bearing replacement required.
Oil pump is damaged - Repair or replace.

Engine noise or knocking

Not enough engine oil - Fill up the engine oil.
Engine is not warmed up to the required temperature - Warm up the engine.
Wrong setting of fuel injection pump timing - Adjust according to specifications.
Incorrect low idle setting - Adjust the low idle speed.
Fuel injectors are faulty or clogged - Clean fuel injectors or change it.
Connecting rod is defective or not aligned - Connecting rod needs to be aligned or changed.
Pistons are broken or worn - Replace the pistons.

Transmission Troubleshooting
Low transmission pressure

Transmission fluid insufficient - Checking transmission fluid level and add if necessary.
Clogged transmission oil filter element (if fitted) - Service or change transmission oil filter.
Relief valve malfunction - Replace relief valve.

Transmission noise

Low fluid level - Fill the transmission housing to proper fluid level.
Transmission fluid is dirty - Transmission fluid change required.
Defective gears or improper backlash - Change the gears or set backlash properly.
Worn or damaged bearings - Bearings replacement required.
Worn or bent shift forks - Change defective shift forks.
Shaft splines are worn or damaged - Replace the shaft.

Gear hard to shift

Rusty or worn gear shift linkage - Install new shift linkage.
Damaged or worn gear shift forks - Install new shift forks.
Gearshift mechanism malfunction - Identify and replace failed parts.
Unadjusted or worn clutch - Change or adjust clutch.

Transmission oil leaking

High transmission fluid level - Drain the excess fluid.
Damaged gaskets or seals - Gaskets or seal need to be replaced.

Hydrostatic Transmission Troubleshooting
Excessive hydrostatic transmission noise

Transmission fluid is dirty or fluid level is too low - Top up to proper level or change transmission fluid.
Worn or out of adjustment speed control linkage - Adjust or install new linkage.
Defective relief valve - Replace relief valve as required.
Transmission overload - Reduce the load is required.
Worn or defective parts of the hydrostatic transmission - Replace or repair defective components.

Loss of power

Lack of transmission fluid - Add fluid to the transmission housing.
Relief valve failure - Replace valve as required.
Speed control linkage is worn or unadjusted - Adjust or repair linkage.

Hot transmission oil

Transmission fluid level is low - Need to add transmission fluid.
Transmission fluid filter element clogging - Service or change transmission fluid filter.
Plugged or defective cooling components - Check all cooling components and change or clean if required.
Transmission overload - The load should be reduced.

Transmission oil leakage

Damaged seals or gaskets - Replace worn gaskets or seal.
High internal transmission case pressure - Replace worn components.
Clogged oil drain line - Clean or replace drain line.

Hydraulic System Troubleshooting
Hydraulic oil pressure too low

Insufficient hydraulic oil - Need to add oil.
Clogged hydraulic fluid filter element - Service the hydraulic filter or change if required.
Defective hydraulic pump - Replace or repair hydraulic oil pump.
Incorrect adjusted hydraulic spool valve - Adjust the spool valve correctly.
Damaged hydraulic cylinder - Change or repair hydraulic cylinder.
Leaks in hydraulic lines - Find leaks in the system and fix it.

Hydraulic system is too hot

Main relief valve malfunctioning - Install a new relief valve.
Wrong hydraulic fluid type - Pour the proper type of fluid.
Hydraulic fluid is dirty - Hydraulic fluid change required.
Air in hydraulic system - Bleed air from hydraulic system.

Hitch does not raise or raises very slowly

Excessive loading on the hitch - Reduce hitch load.
Low hydraulic fluid level - Fill up the hydraulic fluid.
Clogged hydraulic fluid filter - Service the hydraulic filter or change if required.
Hydraulic pump malfunction - Replace or repair hydraulic fluid pump.
Main relief valve is damaged - Relief valve must be changed.
Damaged hydraulic spool valve - Repair or change the valve.
Faulty hydraulic cylinder - Replace or repair hydraulic cylinder.
Suction line is broken or disconnected - Connect or replace.

3-point hitch won't lower or lowers slowly

Incorrect adjusted hydraulic spool valve - Adjust the spool valve correctly.
Hydraulic cylinder failure - Replace or repair hydraulic cylinder.
Misadjusted hitch - Adjust the 3-point hitch.
Damaged hitch rock shaft - Change the shaft.

Hitch drop or lift is jerky

There is air in the hydraulic system - Bleed hydraulic system.
Dirty hydraulic oil - The oil must be changed.
Hydraulic pump not working - Replace or repair hydraulic oil pump.
Damaged hydraulic spool valve - Replace or repair the valve.
Hydraulic cylinder failure - Repair or install a new hydraulic cylinder.

Steering System Troubleshooting
Heavy steering

Incorrectly mounted or defective steering column - Mount the steering column correctly or replace it.
Air trapped inside steering system - Bleed air.
Improper toe-in - Check and adjust toe-in.
Front tyres are worn unevenly - Install new tyres.
Worn steering pump - Check the steering pump and replace if necessary.
Steering pump control valve is faulty or stuck - 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 play

Steering column shaft or coupling is worn out - Replace faulty component.
Steering pump stopped working - Install a new steering pump.
Worn or loose steering linkage joints - Check and replace as required.

Front wheels wander to left or right

Uneven tyre pressure - Inflate the tyres properly.
Incorrect toe-in - Check toe-in and correct.
Steering linkage joints are worn or loose - Inspect and replace as required.
Improperly adjusted or worn front wheel bearings - Adjust correctly or change bearings.

Electrical Troubleshooting
Battery is not charging

Loose or corroded cable connections - Tighten or service connections.
Defective battery terminal connectors - Replace terminal connectors.
Defective battery - Change the battery.
Worn or loose belt - Change belt or adjust belt tension.

Starter turns slow

Low battery voltage - Battery is drained, recharge it.
Battery drains quickly - Service charging system or replace battery.
Bad battery terminals or disconnected wiring - Connect wiring properly or install new terminals.

Starter motor won't turn

Battery is discharged or worn - Charge or replace the battery.
Battery cables are disconnected or incorrectly connected - Check cables and connect as needed.
Low battery voltage - Low battery charging, charge as required.
Starter motor failing - Change or repair starter.



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