Mahindra 35 Series User manual

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INDEX
SERVICE MANUAL
3535 / 4035 / 4535 / 5035
GEAR
'35' Series 4WD
Main Page

PAGESD E S C R I P T I O N
Index
GROUP : A
GENERAL
General........................................................................................... A1 – A21
Introduction .................................................................................. C3 – C18
Manifolds, 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
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 – E54
Wet Clutch PTO ........................................................................... E55 – E58
Brakes .......................................................................................... E59 – E65

PAGESD E S C R I P T I O N
Index
GROUP : G
ELECTRICALS
Electrical System ........................................................................... G1 – G28
GROUP : I
HYDRAULICS
Hydraulics ........................................................................................ 1 – I37
Auxiliary Valve ............................................................................... 38 – 40
I
I I
GROUP : 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

A-1
35 Series 4WD, Model - 3535, 4035, 4535 and 5035 SM June’08
Remember that YOU are the key to safety. Good
safety practices not only protect you, but also the
people around you. Study the features in this
manual and make them a working part of your
safety program. Keep in mind that this safety section
is written only for this type of machine. Practice
all other usual and customary safe working
precautions, and above all - REMEMBER - SAFETY
IS YOUR RESPONSIBILITY. YOU CAN PREVENT
SERIOUS INJURY OR DEATH.
SAFETY - DANGER, WARNING and CAUTION
Whenever you see the words and symbols shown
below, used in this book and on decals, you MUST
take note of their instructions.
The symbol and the word
DANGER indicates an imminently hazardous
situation with, if not avoided, will result in DEATH
OR SERIOUS INJURY.
The symbol and the word
WARNING indicates a potentially hazardous
situation. If the instructions or procedures are not
correctly followed it could result in PERSONAL
INJURY, OR LOSS OF LIFE.
The symbol and the word
CAUTION identifies special instructions or procedure
which if not strictly observed, could result in
DAMAGE, DESTRUCTION OF EQUIPMENT, OR
PERSONAL INJURY.
NOTE : The word NOTE indicates points of
particular interest for more efficient and
convenient repair or operation.
Safety Notes
SAFETY - ALERT SYMBOL AND TERMS
This Safety Alert Symbol means ATTENTION!
BE ALERT! YOUR SAFETY IS INVOLVED!
The safety alert symbol identifies important
safety messages on machines, safety signs,
in manuals, or elsewhere. When you see
this symbol, be alert to the possibility of
personal injury or death. Follow the
instructions given in 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 which could result in a serious injury.
3. Be sure to reinstall safety devices, guards or
shields after adjusting and/or servicing the
machine.
4. After servicing, be sure all tools, parts, or
servicing equipment are removed from the
machine.
5. Use a safety catch on all hoist hooks. Do not
take a chance, the load could slip off the
hook.
6. Electrical storage batteries give off explosive
hydrogen gas when charging and continue
to do so for some time after receiving a steady
charge. Do not under any circumstances allow
an electric spark or an open flame near the
battery. Always disconnect a battery cable
before working on the electrical system.
Always wear safety goggles when servicing
batteries.
7. Use proper tools to make repairs, using
hammers and chisels or punches when pullers
should be used increases the probability of
injury.
8. Be careful when using compressed air to dry
parts. Use approved air blow guns, do not
exceed 30 psi, wear safety glass or goggles
and use proper shielding to protect everyone
in the work area.
9. Do not wear rings, wrist watches or loose
fitting clothing when working on machinery
because they could catch on moving parts
causing serious injury. Wear sturdy,
roughsoled work shoes. Never adjust and/or
service a machine with bare feet or while
wearing sandals or sneakers.
10. Exhaust gases are highly poisonous!
Therefore, do not start the engine in closed
rooms unless adequate ventilation is ensured.
General

35 Series 4WD, Model - 3535, 4035, 4535 and 5035 SM June’08
Group-A
General
General.......................................................................... A1 – A21

A-1
35 Series 4WD, Model - 3535, 4035, 4535 and 5035 SM June’08
Remember that YOU are the key to safety. Good
safety practices not only protect you, but also the
people around you. Study the features in this
manual and make them a working part of your
safety program. Keep in mind that this safety section
is written only for this type of machine. Practice
all other usual and customary safe working
precautions, and above all - REMEMBER - SAFETY
IS YOUR RESPONSIBILITY. YOU CAN PREVENT
SERIOUS INJURY OR DEATH.
SAFETY - DANGER, WARNING and CAUTION
Whenever you see the words and symbols shown
below, used in this book and on decals, you MUST
take note of their instructions.
The symbol and the word
DANGER indicates an imminently hazardous
situation with, if not avoided, will result in DEATH
OR SERIOUS INJURY.
The symbol and the word
WARNING indicates a potentially hazardous
situation. If the instructions or procedures are not
correctly followed it could result in PERSONAL
INJURY, OR LOSS OF LIFE.
The symbol and the word
CAUTION identifies special instructions or procedure
which if not strictly observed, could result in
DAMAGE, DESTRUCTION OF EQUIPMENT, OR
PERSONAL INJURY.
NOTE : The word NOTE indicates points of
particular interest for more efficient and
convenient repair or operation.
Safety Notes
SAFETY - ALERT SYMBOL AND TERMS
This Safety Alert Symbol means ATTENTION!
BE ALERT! YOUR SAFETY IS INVOLVED!
The safety alert symbol identifies important
safety messages on machines, safety signs,
in manuals, or elsewhere. When you see
this symbol, be alert to the possibility of
personal injury or death. Follow the
instructions given in 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 which could result in a serious injury.
3. Be sure to reinstall safety devices, guards or
shields after adjusting and/or servicing the
machine.
4. After servicing, be sure all tools, parts, or
servicing equipment are removed from the
machine.
5. Use a safety catch on all hoist hooks. Do not
take a chance, the load could slip off the
hook.
6. Batteries give off explosive hydrogen gas
when charging and continue to do so for
some time after receiving a steady charge.
Do not under any circumstances allow
an electric spark or an open flame near the
battery. Always disconnect a battery cable
before working on the electrical system.
Always wear safety goggles when servicing
batteries.
7. Use proper tools to make repairs, using
hammers and chisels or punches when pullers
should be used increases the probability of
injury.
8. Be careful when using compressed air to dry
parts. Use approved air blow guns, do not
exceed 30 psi, wear safety glass or goggles
and use proper shielding to protect everyone
in the work area.
9. Do not wear rings, wrist watches or loose
fitting clothing when working on machinery
because they could catch on moving parts
causing serious injury. Wear sturdy,
roughsoled work shoes. Never adjust and/or
service a machine with bare feet or while
wearing sandals or sneakers.
10. Exhaust gases are highly poisonous!
Therefore, do not start the engine in closed
rooms unless adequate ventilation is ensured.
General

A-6
35 Series 4WD, Model - 3535, 4035, 4535 and 5035 SM June’08
General
B-10 Gaskets & Seals
During installation, take care not to damage
seals or gaskets. Pack lip type seals with
grease and use sleeve when a seal has to be
passed over splines or threads.
Always use new gaskets seals, cotter pins
during assembly.
C. STANDARD NUT AND BOLT
C-1 Torque Data
The following table is applicable to all
standard nuts and bolts providing :-
I. All threads are clean and lubricated
with engine oil or chassis grease.
II. Standard height nuts are used on
tapped holes contains an equivalent
amount of threads.
III. No gaskets or compressionable
materials are used.
Where a special torque, differing from the
table, is required for a particular application,
this is mentioned in the section concerned.
BOLT TYPE 2 TYPE 4
SIZE Min. Max. Min. Max.
(lb.-ft.) (lb.-ft.)
1/4” 9 - 10 12 - 14
5/16” 18 - 21 25 - 28
3/8” 32 - 36 45 - 50
7/16” 51 - 57 72 - 81
1/2” 75 - 85 110 - 125
9/16” 110 - 125 160 - 180
5/8” 155 - 175 220 - 245
3/4” 270 - 310 385 - 435
7/8” 405 - 455 625 - 700
1” 600 - 700 950 - 1050
B. INSPECTION & REPAIR
The following notes should be used as a
general guide for inspection and repair.
Where a special procedure is necessary for
a component or assembly, full details will be
found in 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. It is usually
advisable to replace such pins/circlips while
overhauling.
B-4 Gears & Spline
Check for cracks, pitting, burrs, broken
chipped teeth. Check for excessive wear with
mating parts. Dress off burrs from gears and
splines with a fine carborundum stone; care
must be taken to remove the burr only.
DO NOT interfere with the tooth or spline
profile. REPLACE all parts which show signs
of damage or excessive wear.
B-5 Welds
Check all welded assemblies for cracks, twisting
& misalignment. Information concerning the
use of special welding rods or welding
procedure is detailed, where relevant, in the
appropriate section of the group.
B-6 Castings
Check castings for cracks and distortion.
B-7 Fuel Tanks
Check for leaks.
B-8 Fuel, Oil and Coolant Pipes and Hoses
Check unions for leaks, stripped threads or
other faults. Check pipes for cracks or chafing,
hoses for chafing, twisting or other damage.
B-9 Lubrication Fittings
Check for damage of missing fittings and
replace. Check that grease and oil galleries
are clear.

A-7
35 Series 4WD, Model - 3535, 4035, 4535 and 5035 SM June’08
C-2 The following table gives conversion factors
for use in converting the British specifications
to their metric equivalents:
To Convert From To Multiply By
inch cm 2.54000
lb kg 0.45360
ounce kg 0.02835
lb-ft kg-m 0.13821
lb-in kg-m 0.01152
lb/sq in kg/sq.cm. 0.07031
imp gallons litre 4.54609
imp pint litre 0.56826
SI Unit English Equivalent
mm - Millimeter 0.039 inches
cm - Centimeter 0.39 inches
cm3- Cubic Centimeter 0.06 cubic in.
m3- Cubic Meter 35.31 cubic ft.
l - Litre 1.057 quarts
kg - Kilogram 2.205 pounds
kPa - Kilo Pascal 0.145 psi
MPa - Mega Pascal 145.00 psi
N - Newton 0.225 pounds force
DaN - Deka Newton 2.25 pounds force
Nm - Newton Meter 0.738 foot pounds force
DaNm-Dekanewton meter 7.38 foot pounds force
OC degrees - Celsius 1.8xOC+32 Fahrenheit
kW - Kilowatt 1.34 horse power
l/min - liter/minute 0.219 gallon per minute
km/h - Kilometer/hour 0.621 mile per minute
Scale 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 22.22 296.0 to 332.0 41.0 — 46.0
1 25.40 441.0 to 491.0 61.0 — 68.0
Diameter of bolt Fine thread (NF)
Inch mm lb-ft kg-m
1/4 6.35 006.5 to 008.0 00.9 — 01.1
5/16 7.94 013.7 to 015.2 01.9 — 02.1
3/8 9.52 021.7 to 023.9 03.0 — 03.3
7/16 11.11 035.4 to 039.1 04.9 — 05.4
1/2 12.70 043.4 to 050.6 06.0 — 07.0
9/16 14.29 068.7 to 076.0 09.5 — 10.5
5/8 15.88 083.2 to 094.0 11.5 — 13.0
3/4 19.05 145.0 to 159.0 20.0 — 22.0
7/8 22.22 224.0 to 246.0 31.0 — 34.0
1 25.40 290.0 to 325.0 40.0 — 45.0
Metric
standard Metric thread
designation lb-ft kg-m
M-4 001.5 to 002.2 00.2 — 00.3
M-6 005.8 to 007.2 00.8 — 01.0
M-8 014.5 to 016.6 02.0 — 02.3
M-10 029.0 to 032.5 04.0 — 04.5
M-12 047.7 to 055.0 06.6 — 07.6
M-14 076.0 to 086.7 10.5 — 12.0
M-18 159.0 to 181.0 22.0 — 25.0
General

A-8
35 Series 4WD, Model - 3535, 4035, 4535 and 5035 SM June’08
HANDLING PRECAUTIONS FOR ELECTRICAL PARTS
AND WIRING
To ensure safety and prevent damage to the Machine
and surrounding equipment, the following precautions
needs to be taken while handling electrical parts & wiring.
IMPORTANT :
• Check electrical wiring for damage and Loosened
connection every week.
• Do not attempt to modify or remodel any
electrical parts and wiring.
• When removing the battery cable, disconnect the
negative wire first. When Installing the battery
cable, connect the positive first.
• After connecting cables to battery terminals apply
petroleum jelly to them and securely install
terminal covers on them.
• Do not allow dirt and dust to get collected on battery.
• Take care not to let battery liquid spill on 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
harness.
• Do not pour water on electrical parts such as main
switch and alternator.
OIL, DUST AND DIRT
• If flammable material such as fuel, or Lubricant
spills, wipe it off with dry piece of cloth, Do not
approach it with an open flame.
• Replace fuel pipe that is aged.
• Remove dirt and dust accumulated on heated
parts, wiring harness battery etc.
• Use sand paper to remove corrosion, rust from
terminal.
• Repair deformed terminal. Make sure there is no
terminal being exposed or displaced.
• Make sure certain plastic cover is large enough
to cover whole connector.
General
Negative
(–)
Positive
(+)

A-9
35 Series 4WD, Model - 3535, 4035, 4535 and 5035 SM June’08
Operational safety and efficient performance are the
qualities required for a farm tractor. If it is to fulfil its
essential function of replacing manpower and
rationalizing farm economy.
This does not only call for a good demonstration when
the tractor is handed over to the customer, but also for
the ever-ready service of a dealer who is quick to spot
the source 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, therefore, advisable to
keep both these manuals in the same place.
After carefully studying this book every serviceman should
be able to overhaul a tractor completely in his workshop
equipped with special tools.
Notes
General

A-10
35 Series 4WD, Model - 3535, 4035, 4535 and 5035 SM June’08
Single Parts Repair, Off-Season Inspection
or General Overhaul
Overhauling a tractor could be essentially
different in the following respects :
1) The repair of individual parts that has
failed during operation. This kind of
repair is by no means as easy as it may
seem at first sight, for replacing the
defective part may call for elaborate
and extensive dismantling and
reassembly procedures. Another
disadvantage of a “single parts repair”
is that it may have to be carried out
during the working season when the
tractor is most urgently needed. When
taking the preventive maintenance
measures as outlined below these
“single parts repairs” should, to a
great extent, be eliminated.
2) A fundamentally different procedure
is the “off-season inspection” when
all parts of the machine are checked
over. This procedure covers mainly the
following : Thorough cleaning of the
machine, re-setting and adjusting of
all units subject to a certain amount
of wear, replacing those parts which
still function but show such a degree
of wear that they are not likely to
survive the ensuing working season.
Off-season inspection 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 tractor is
seldom required to do any work.
During this period service stations do
not have much to do as a rule and
can give better service than during the
peak periods.
3) A rather expensive reconditioning job
is the “general overhaul”. It becomes
necessary when the tractor has been
kept on the job by “make-shift”
repairs without observing
fundamental maintenance rules. Worn
parts fail and other, potentially good
parts are often broken as a result of
these failures.
Apart from being a costly affair it very
often happens that this sort of repair
has to be made during the operating
season when work is pressing.
A general run down condition,
moreover, often causes small fissures
and cracks which can be overlooked
and are then the source of fresh
trouble.
Off-season inspection is the most
important measure of preventive
maintenance. The frequency of this
inspection should be determined by
the number of operating hours and
by operating conditions.
General

A-11
35 Series 4WD, Model - 3535, 4035, 4535 and 5035 SM June’08
General Recommendation for
disassembly and assembly operations
Before the tractor is accepted in the workshop, all
external surfaces must be thoroughly cleaned.
The service station must be clean and well lit. Strict
cleanliness must be observed when engine,
transmission and hydraulic systems are repaired.
A tractor repair shop should not be without at least
one good lifting crane so that engines and
transmissions can be removed and installed without
hazard. Suitable wooden mounting blocks, easily
accessible from all sides, on which engines and
transmissions can be placed, should be available.
They can easily be made locally.
Before dismantling, drain all water, fuel and oil from
the tractor.
It is good practice to check compression of each
cylinder before dismantling the engine to get
general ideal on the condition of the compression
building elements, such as pistons, sleeves, gaskets,
etc.
A comparison of compression readings of these
figures will disclose errors or show improvements.
Whenever reference is made to “Cleaning” in the
various sections of this book it should be taken
mean thorough cleaning i.e. complete removal oil,
grease, impurities, foreign matter and burr etc.
Even the smallest contaminants may cause serious
trouble!
Follow the disassembly and assembly procedures
in this book. They are based on years of practical
experience and provide the quickest reliable repair
procedure.
After removing oil, grease, etc., arrange parts on
a clean table in the order in which they belong to
prevent confusion later. A suitable installation to
remove oil, grease, dirt etc. from parts should be
available in every tractor repair shop.
A small boiler and a good solvent are ideal for this
purpose.
Before reassembly, carefully inspect all parts whether
they can be re-used. Ball and roller bearings must
be washed in kerosene. 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
paper. A badly worn bearing makes a rattling,
chain-like noise.
Do not remove the original oil paper wrapping from
new ball bearings until just before sliding them on
shafts. The grease coating applied by the bearing
factory must not be removed unless this is necessary
for cleanliness reasons.
Warm press-fit ball bearings in clean 800C (1750F)
oil and slide them on shafts as quickly as possible.
When assembling, apply some transmission oil to
all moving parts, especially to bearings, to provide
an oil film until the regular pressure feed lubrication
takes over.
In order to eliminate errors all steps, such as
adjustments, settings, and the various phases of
assembly and disassembly procedures, must be
considered without haste and with common sense.
It is better to check three times than commit one
error.
Put all new felt seals and gaskets in 500C. (1220F)
warm oil and allow to soak before installing them.
Apply some soft soap or soap solution to all rubber
hose connections before installation.
Always install oil seal with the sealing lip towards
the oil side. Prior to assembly apply some engine
oil to the sealing lip. Generally oil seals are a press
fit in their bores and the steel casing is slightly
compressed in assembly. Used oil seals have lost
tension and the required pressfit can no longer be
obtained. For this reason, never reuse oil seals even
though the sealing lip may still be in good
condition. Should an emergency arise, install the
reused oil seal with some liquid sealer.
Expansion plugs should be oil tight. Use some
sealing compound and fit the plug with its concave
side out. Spread the plug by driving carefully on
its center with suitable installing tool.
General

A-12
35 Series 4WD, Model - 3535, 4035, 4535 and 5035 SM June’08
Secure all nuts by using good spring lock washers or
external tooth lock washers except for cylinder head,
brass and castellated nuts, which are secured by special
methods.
Gaskets and O-rings must be replaced during reassembly.
Apply grease to new O-rings or oil seals before
assembling. See the figure left side.
When reassembling external snap rings or internal snap
rings, they must be positioned so that sharp edge faces
against the direction from which a force is applied.
See the figure left side.
To prevent damage to the hydraulic system, use only
specified fluid or equivalent.
Castellated nuts must be carefully secured with cotter
pins. Spread cotter pins as shown on the right nut
below. Be sure that pins seat tightly so that they will
not work loose.
When 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 moisture, rust and
corrosion have access where bolts and nuts were
loosened and the original paint coat has been broken.
The original paint (Tractor Red) is available at all
Establishments.
For all procedures described in this manual a certain
amount of skill and craftsmanship is required.
Wherever the terms RIGHT and LEFT are used they are
understood to mean the right and left sides when facing
forward in the tractor seat. Reference to FRONT indicates
the radiator end of the tractor and REAR the drawbar
end.
1. Grease
2. Force
3. Sharp Edge
4. Axial Force
5. Rotating Movement
A. External Snap Ring
B. Internal Snap Ring
General

A-13
35 Series 4WD, Model - 3535, 4035, 4535 and 5035 SM June’08
Priming the Lubrication System
NOTE : Diesel engines must not be rotated when
priming with oil; otherwise, they are likely
to start running.
When assembling the overhauled engine, it is
necessary to thoroughly lubricate the various
running parts with clean engine oil to assure initial
lubrication when engine is first started.
However, to further make certain that complete
initial lubrication is available, the engine lubricating
system should be pressure primed or charged with
oil. Attach the line from a priming device to a
suitable fitting located in the main oil gallery, filter
header or oil cooler of the engine and inject
sufficient oil into the engine to fill the oil filters
and charge the entire system. Use only clean engine
oil in accordance with Operator’s Manual. New or
overhauled engines that have been in storage over
an extended period should also be primed
in a similar manner.
After the priming procedure is completed, make
certain that the oil level is checked before the engine
is put into service. Do not overfill the engine; neither
should engine be short of oil as a result of using
the pressure priming procedure.
Priming the engine will minimize the possibility of
scuffing or heat build-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 cooling system is filled correct level
d) Precautions for alternator operation are
observed.
Run-in
1. Start and run engine at 3/4 rated engine
speed with no load, until operating
temperature (80-850C) (164-1720F) is reached,
cover the radiator if necessary, DO NOT run
for over 10 Minutes.
2. Retorque cylinder head bolts.
DO NOT run the engine longer
than 15 Minutes, before retorquing cylinder head
bolts.
3. Continue according to the following chart.
with Dynamometer
Engine Load Time
RPM % minutes
1400 40 5
2000 50 5
rated speed 80 10
100 below rated speed 50 10
without Dynamometer
(In-Vehicle Run-in Procedure)
Engine Load Time
RPM % minutes
3/4 of rated light 5
3/4 of rated medium 15
rated speed full 20
After Running-in
Retighten manifold bolts and/or stud nuts.
Re Torque the cylinder bolts and check valve
clearance and readjust as necessary.
Handing over the Engine
In the presence of the operator check engine oil
level and coolant level. Test run the engine.
Point out to the operator that the overhauled engine
is to be treated in the same way as a new one.
General

A-14
35 Series 4WD, Model - 3535, 4035, 4535 and 5035 SM June’08
CHECK AND MAINTENANCE
Be sure to check and service the tractor on a flat
and clean place with engine shut off, parking brake
on and blocked wheels.
(1) Daily check
To prevent trouble from occurring, it is
important to know the condition of the
tractor, check the following items.
CHECKING
• Checking areas where previous trouble was
experienced.
• Walk around the tractor.
1. Check the tire pressure and check for wear
and damage.
2. Check for oil and water leakage.
3. Check the engine oil level.
4. Check Transmission fluid level.
5. Check coolant level.
6. Check and clean the radiator screen and grill.
7. Check the condition of ROPS attaching
hardware.
8. Check the bolts & Nuts of the wheels.
9. Condition of danger, warning and caution
labels.
10. Clean around the exhaust manifold and the
muffler of the engine.
11. Check fan belt tension.
• While sitting in the operator’s seat
1. Check the working condition of the throttle
pedal, brake pedals and clutch pedal.
2. Check the parking brake.
3. Check the 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 and keep
them tight.
Checking Radiator hoses and clamps.
- If hose clamps are loosen or water leaks,
tighten clamps securely.
- If radiator hoses are swollen, hardened or
cracked replace hoses and clamps.
- Check all power steering line, fuel line, clamps
and hoses.
- If these found damage, replace them.
Sr. Application Capacity Anticipated minimum air temperature
No. Gallon / Litres –40 to +880F –22 to +880F –4 to +1220F +32 to +1040F +50 to +1220F
1. Crankcase 3 Cyl. 1.58 / 6.34 SAE 15W40 SAE 15W40 SAE 15W40 SAE 15W40 SAE 15W40
4 Cyl. 2 / 8.03
2. Transmission & 9.2 / 36.8 SAE 75W UTTO SAE 80W UTTO listed above.
Hydraulics
3. Lubrication Fittings C. L. NLGI No. as recommended
4. Front Axle - 3535 1.71 / 6.84 SAE75W90EP SAE80W140EP SAE80W90EP SAE80W140EP
4035, 4535 & 5035 2.24 / 8.98 SAE80W90EP listed above for ambient temperature range - 40F to 1040F
Oil Specifications Chart

A-15
35 Series 4WD, Model - 3535, 4035, 4535 and 5035 SM June’08
Distance should be same at the front and rear.
Front Axle - Front Wheel “Toe-in” Check
In the event of the tie rod setting, then it is necessary
to adjust the TOE-IN. Before measuring and adjusting
the TOE-IN, ensure the front wheels are in the
straight ahead position and the front axle is not
tilted.
After adjusting the front wheel tread and with all
connections secured, the front wheel Toe-in shall be
as follows,
Toe-in Value
35 Series Inch mm
4WD 0 – 0.23 0 – 6
Measure the distance between the outer edges of the
wheel rims at the same height as the hub caps.
Mark the point measured and turn the wheels half
revolution so that the marked points are at the rear.
Measure again 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 angle
the welded stop on the steering knuckle pivot pin sleeve
should be hard against the stop on the steering knuckle.
Adjusting Valve Clearance
Adjusting Engine valve clearance at every 800 hours.
To check valve clearance use the simplified procedure
as out lined in the following.
All Values can be adjusted by cranking the engine only
twice.
No 1 Piston at T.D.C. (Compression)
Adjust Valves (Engine Warm)
1245
No 4 Piston at T.D.C Compression
Adjust Valves (Engine warm)
3678
Inlet 0.010 inch (0.25mm)
Exhaust 0.012 inch (0.3mm)
General

A-16
35 Series 4WD, Model - 3535, 4035, 4535 and 5035 SM June’08
General
SOP for Rotary FIP timing checking on tractor
1. Remove engine starter.
2. Ensure that the position of timing pointer on front
cover which mets with crank pulley punched line.
3. Remove high pressure pipe at Fuel injection
pump end.
4. Remove special plug provided 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 specified
reading.
Injection Timing (mm@tdc)
For 4035 / 3535 — 0.95 ± 0.02 mm
For 4535 / 5035 — 1.00 ± 0.02 mm
Fig. 1
Fig. 2
For 3 Cyl. For 4 Cyl.

A-17
35 Series 4WD, Model - 3535, 4035, 4535 and 5035 SM June’08
General
A
C
B
SOP for adjusting Clutch 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 clutch linkage as shown below.
Free Play - Distance 0.78 to 0.98 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. Loosen jam nut (B).
2. Turn the Turn Buckle (C) anticlockwise to increase
play and clockwise to decrease play.
CB