Mahindra 35 Series Service Manual
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Mahindra 35 Series Service Manual

Mahindra 35 Series Service Manual

4wd
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SERVICE MANUAL
'35' Series 4WD
3535 / 4035 / 4535 / 5035
GEAR
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Summary of Contents for Mahindra 35 Series

  • Page 1 SERVICE MANUAL '35' Series 4WD 3535 / 4035 / 4535 / 5035 GEAR Click here to go on INDEX Main Page...

  • Page 2: Table Of Contents

    Index D E S C R I P T I O N PAGES GENERAL GROUP : A General................... A1 – A21 SPLITTING THE TRACTOR GROUP : B Splitting of Tractor ................ B1 – B32 ENGINE GROUP : C Introduction .................. C3 – C18 Manifolds, Cylinder Head &...
  • Page 3 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...
  • Page 4 Exhaust gases are highly poisonous! particular interest for more efficient and Therefore, do not start the engine in closed convenient repair or operation. rooms unless adequate ventilation is ensured. 35 Series 4WD, Model - 3535, 4035, 4535 and 5035 SM June’08...

  • Page 6: Group-A

    Group-A G e n e r a l General ................A1 – A21 35 Series 4WD, Model - 3535, 4035, 4535 and 5035 SM June’08...
  • Page 8 Exhaust gases are highly poisonous! particular interest for more efficient and Therefore, do not start the engine in closed convenient repair or operation. rooms unless adequate ventilation is ensured. 35 Series 4WD, Model - 3535, 4035, 4535 and 5035 SM June’08...
  • Page 9 Check pipes for cracks or chafing, hoses for chafing, twisting or other damage. Lubrication Fittings Check for damage of missing fittings and replace. Check that grease and oil galleries are clear. 35 Series 4WD, Model - 3535, 4035, 4535 and 5035 SM June’08...
  • Page 10 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 35 Series 4WD, Model - 3535, 4035, 4535 and 5035 SM June’08...
  • Page 11 • 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. 35 Series 4WD, Model - 3535, 4035, 4535 and 5035 SM June’08...
  • Page 12 After carefully studying this book every serviceman should be able to overhaul a tractor completely in his workshop equipped with special tools. 35 Series 4WD, Model - 3535, 4035, 4535 and 5035 SM June’08...
  • Page 13 A-10 35 Series 4WD, Model - 3535, 4035, 4535 and 5035 SM June’08...
  • Page 14 Spread the plug by driving carefully on inspect all parts to see whether they can be re-used. its center with suitable installing tool. Replace if necessary. A-11 35 Series 4WD, Model - 3535, 4035, 4535 and 5035 SM June’08...
  • Page 15 REAR the drawbar end. 1. Grease A. External Snap Ring 2. Force B. Internal Snap Ring 3. Sharp Edge 4. Axial Force 5. Rotating Movement A-12 35 Series 4WD, Model - 3535, 4035, 4535 and 5035 SM June’08...
  • Page 16 (80-85 C) (164-172 F) is reached, cover the radiator if necessary, DO NOT run for over 10 Minutes. Retorque cylinder head bolts. A-13 35 Series 4WD, Model - 3535, 4035, 4535 and 5035 SM June’08...
  • Page 17 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 - 4 F to 104 A-14 35 Series 4WD, Model - 3535, 4035, 4535 and 5035 SM June’08...
  • Page 18 No 1 Piston at T.D.C. (Compression) Adjust Valves (Engine Warm) No 4 Piston at T.D.C Compression Adjust Valves (Engine warm) Inlet 0.010 inch (0.25mm) Exhaust 0.012 inch (0.3mm) A-15 35 Series 4WD, Model - 3535, 4035, 4535 and 5035 SM June’08...
  • Page 19 Injection Timing (mm@tdc) For 4035 / 3535 — 0.95 ± 0.02 mm For 4535 / 5035 — 1.00 ± 0.02 mm Fig. 2 A-16 35 Series 4WD, Model - 3535, 4035, 4535 and 5035 SM June’08...
  • Page 20 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. A-17 35 Series 4WD, Model - 3535, 4035, 4535 and 5035 SM June’08...
  • Page 21 • Securely tighten the cap. If the cap is loose or Improperly fitted, water may lead out and cause the engine overheating. A-18 35 Series 4WD, Model - 3535, 4035, 4535 and 5035 SM June’08...
  • Page 22 Vol % Freezing Point Boiling Point Anti Freeze – 24 – 12 – 37 – 35 A-19 35 Series 4WD, Model - 3535, 4035, 4535 and 5035 SM June’08...
  • Page 23 5. Assemble the new filter. Do not over tighten. 6. Prime the system and bleed the filter. Tighten the bleeding screw. A-20 35 Series 4WD, Model - 3535, 4035, 4535 and 5035 SM June’08...
  • Page 24 * Depends upon the conditions in which the tractor is being operated. Activity due. A-21 35 Series 4WD, Model - 3535, 4035, 4535 and 5035 SM June’08 # Indicates that this must be done initially at specified hrs. Repeat the activity.

  • Page 25: Group-B

    Group-B Splitting the Tractor Splitting the Tractor ............. B1 – B32 35 Series 4WD, Model - 3535, 4035, 4535 and 5035 SM June’08...
  • Page 27 First remove the battery cable from its negative terminal & then remove battery cable from positive terminal. Remove the battery. NOTE : Always disconnect the negative terminal first. Positive Negative (–) 35 Series 4WD, Model - 3535, 4035, 4535 and 5035 SM June’08...
  • Page 28 Loosen the Air cleaner inlet hose, connections from the intake manifold and air cleaner. Remove air cleaner by removing it from bracketaries. Remove the radiator inlet and outlet hoses. 35 Series 4WD, Model - 3535, 4035, 4535 and 5035 SM June’08...
  • Page 29 Disconnect the LH / RH hoses to the power steering cylinder and plug the hoses to prevent oil spillage. Remove the propeller shaft guards. Remove the propeller shaft bearing from support bracket. 35 Series 4WD, Model - 3535, 4035, 4535 and 5035 SM June’08...
  • Page 30 Start Engine and rotate the steering wheel in both directions for few times until the Air trapped in the pipelines is expelled. Check for steering noise and vibrations. 35 Series 4WD, Model - 3535, 4035, 4535 and 5035 SM June’08...
  • Page 31 F/R Neutral switch, Fuel line wiring harness from central wiring harness. Disconnect wiring harness to the relay box. Disconnect the fuel lines between Fuel filter & fuel tank. 35 Series 4WD, Model - 3535, 4035, 4535 and 5035 SM June’08...
  • Page 32 Remove the wiring harness from firewall clamps completely. Dismantle the Fire wall assembly from front platform. Dismantle hood mounting support bracket. Dismantle Dust cover from clutch hosing. 35 Series 4WD, Model - 3535, 4035, 4535 and 5035 SM June’08...
  • Page 33 Engine towards clutch housing. Allow the splines of clutch plate to align with those on the main shaft hollow shuttle section. 35 Series 4WD, Model - 3535, 4035, 4535 and 5035 SM June’08...
  • Page 34 Drain the oil completely from the transmission housing using drain plug. Disconnect the fuel lines between fuel filter & fuel tank. Remove the LH side foot step . B-10 35 Series 4WD, Model - 3535, 4035, 4535 and 5035 SM June’08...
  • Page 35 Filter to oil pump & plug the pipes. Dismantle the oil filter. Disconnect the brake linkages at brake actuating lever. Remove the seat from mounting channels with LH & RH mounting channels. B-11 35 Series 4WD, Model - 3535, 4035, 4535 and 5035 SM June’08...
  • Page 36 Remove the differential lock foot pedal. Removing of Control Levers Knob Remove the isolator mounting bolts from Rear platform. Dismantle the rear platform. Dismantle the isolator mounting bracket from Rear Axle. B-12 35 Series 4WD, Model - 3535, 4035, 4535 and 5035 SM June’08...
  • Page 37 Rear Axle. Move the rear axles away from the transmission case. REJOINING THE TRANSMISSION AND REAR AXLE Follow the reverse sequence of Splitting for rejoining. B-13 35 Series 4WD, Model - 3535, 4035, 4535 and 5035 SM June’08...
  • Page 38 B-14 35 Series 4WD, Model - 3535, 4035, 4535 and 5035 SM June’08...
  • Page 39 4. Install pins (C) and quick-lock pins (B). 5. Tighten the knob (D). A - ROPS rollbar B - Quick-lock Pins C - Headed Pins D - Knob ROPS Folded B-15 35 Series 4WD, Model - 3535, 4035, 4535 and 5035 SM June’08...
  • Page 40 4. Support the ROPS rollbar to avoid any injury. 5. Loosen bolts (B) & nuts (C) from ROPS mounting from both rear axle carrier. 6. Follow the reverse sequence of removal for refitment of ROPS. B-16 35 Series 4WD, Model - 3535, 4035, 4535 and 5035 SM June’08...
  • Page 41 Follow the reverse sequence of removal for refitment. Align the hood resting area equally and properly, before tightening the four hood mounting nuts. B-17 35 Series 4WD, Model - 3535, 4035, 4535 and 5035 SM June’08...
  • Page 42 Refit the fender in the reverse sequence of removal. Align the fender resting area equally and properly, before tightening the fender mounting nuts. B-18 35 Series 4WD, Model - 3535, 4035, 4535 and 5035 SM June’08...
  • Page 43 Removal & Refitment of Seat Loosen the seat mounting nuts (A) from the bracket (B). Remove the seat. Refit the removed parts in the reverse sequence of removal. B-19 35 Series 4WD, Model - 3535, 4035, 4535 and 5035 SM June’08...
  • Page 44 Check the "Tank Unit" fuel gauge sensor is working properly. Refitment of the Fuel Tank Reverse the removal procedure. Fill the tank with clean fuel and bleed the system. B-20 35 Series 4WD, Model - 3535, 4035, 4535 and 5035 SM June’08...
  • Page 45 Remove the battery. Refitment of the Battery Refit the removed parts in the reverse sequence of removal. Refit the Battery Negative cable only at the end of assembly. B-21 35 Series 4WD, Model - 3535, 4035, 4535 and 5035 SM June’08...
  • Page 46 Refitment of the Starter Motor Refit the removed parts in the reverse sequence of removal. Refit the Battery Negative cable only at the end of assembly. B-22 35 Series 4WD, Model - 3535, 4035, 4535 and 5035 SM June’08...
  • Page 47 Alternator for the required speed. Too tight a belt will impose severe side thrust on the bearings and seriously shorten their life. B-23 35 Series 4WD, Model - 3535, 4035, 4535 and 5035 SM June’08...
  • Page 48 Do not use a slave battery of higher than volts nominal voltage. Always disconnect the battery ground cable before carrying out arc welding on the tractor or any implements attached to the Tractor. B-24 35 Series 4WD, Model - 3535, 4035, 4535 and 5035 SM June’08...
  • Page 49 Open the hood. Loosen the hose clips (A) of hose (B) as well as respective pipes. Loosen the wing nut (C) & turn the clamp (D). Remove air cleaner. B-25 35 Series 4WD, Model - 3535, 4035, 4535 and 5035 SM June’08...
  • Page 50 If Secondary Element is replaced, install new element immediately to prevent dust from entering air intake system. Primary Element Filter Replace Secondary Element (J), if dirty or damaged. Safety Cartridge B-26 35 Series 4WD, Model - 3535, 4035, 4535 and 5035 SM June’08...
  • Page 51 G. STORING ELEMENT If element is not installed on tractor, seal element in a plastic bag and store in its original shipping container to protect against dust and damage. B-27 35 Series 4WD, Model - 3535, 4035, 4535 and 5035 SM June’08...
  • Page 52 Refit the removed components in the reverse sequence of removal. Ensure that the connectors are connected properly and in correct positions. Finally connect the battery positive cable. B-28 35 Series 4WD, Model - 3535, 4035, 4535 and 5035 SM June’08...
  • Page 53 Reassemble the removed components in the reverse sequence of removal. Ensure that the connectors are connected properly and in correct positions. Finally connect the battery positive cable. B-29 35 Series 4WD, Model - 3535, 4035, 4535 and 5035 SM June’08...
  • Page 54 Fit the RH side panel and close the hood. Start engine and operate hydraulics. Check all connections for leaks. Check oil level, add if necessary with the recommended grade of oil. B-30 35 Series 4WD, Model - 3535, 4035, 4535 and 5035 SM June’08...
  • Page 55 5. Refit the strainer. 6. Refit the cover plate and suction filter. For Service / Replacement of strainer contact your Mahindra Dealer. B-31 35 Series 4WD, Model - 3535, 4035, 4535 and 5035 SM June’08...
  • Page 56 When front isolator bracket LH is to be fitted, setting of neutral switch is to be carried out after bracket fitment as per "Refitment of Neutral Safety Switch" mentioned above. B-32 35 Series 4WD, Model - 3535, 4035, 4535 and 5035 SM June’08...

  • Page 57: Engine

    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 35 Series 4WD, Model - 3535, 4035, 4535 and 5035 SM June’08...

  • Page 59: Introduction

    CHAPTER - 1 INTRODUCTION 35 Series 4WD, Model - 3535, 4035, 4535 and 5035 SM June’08...
  • Page 61 250.0 N ± 10% Final length (mm) 32.6 Final load 439.0 ± 10% Free length (mm) 54.40 approx. Spring rate ( at 30-70% of final load) N/mm 20.1 ± 0.8 35 Series 4WD, Model - 3535, 4035, 4535 and 5035 SM June’08...
  • Page 62 Piston pin bore (mm) 28.003 / 28.009 Number of ring grooves Width of ring groove Top groove (3) Reference Value Middle groove 2.550 / 2.570 Bottom groove 4.020 / 4.040 35 Series 4WD, Model - 3535, 4035, 4535 and 5035 SM June’08...
  • Page 63 0.051 / 0.102 COOLING SYSTEM Water pump Impeller shaft dia (mm) Front Ø78.8 ±0.3 ±0.3 Rear Ø78.8 Thermostat Range 80º - 96º CAMSHAFT Material Monochrome cast iron Number of bearings 35 Series 4WD, Model - 3535, 4035, 4535 and 5035 SM June’08...
  • Page 64 Crankcase Front Plate Mounting Bolt G 7.938mm X 19.05 mm 18 to 22 Crankcase Front Plate Mounting Bolt 1/4" UNC X 3/4 8 to 12 Crankcase Front Plate Mounting Screw 4 to 6 35 Series 4WD, Model - 3535, 4035, 4535 and 5035 SM June’08...
  • Page 65 Heat Shield Bolt Nut M10x1.5 25 to 30 Tube Thermostat Bypass 8 to 10 Oil Sump & Adapter Plate Fitment Lubricating Oil Pump To Crankcase 3/8" UNC X 1-1/8 25 to 30 35 Series 4WD, Model - 3535, 4035, 4535 and 5035 SM June’08...
  • Page 66 Valve Housing Cover Nut M10x1.5 mm 8 to 10 Hose Clip For FIP Overflow Pipe 2 to 4 Bolt Banjo M8 X1, Spill Over & Overflow Pipe 12 to 15 C-10 35 Series 4WD, Model - 3535, 4035, 4535 and 5035 SM June’08...
  • Page 67 11) Flywheel ring gear, replaceable. 22) Connecting rod, when installing apply engine NOTE: In overall Engine Section, 3 cylinder oil and see that the number mark at pump pictures shown. side. C-11 35 Series 4WD, Model - 3535, 4035, 4535 and 5035 SM June’08...
  • Page 68 The purpose of the flywheel is to oppose and moderate, by its inertia, any fluctuation in the speed of the engine. It counteracts varying torques during the stroke of the engine and C-12 35 Series 4WD, Model - 3535, 4035, 4535 and 5035 SM June’08...
  • Page 69 Introduction C-13 35 Series 4WD, Model - 3535, 4035, 4535 and 5035 SM June’08...
  • Page 70 The filter has a manual. bypass valve designed to prevent loss of lubricating oil flow if the filter becomes stagged. Oil from the filter enters the C-14 35 Series 4WD, Model - 3535, 4035, 4535 and 5035 SM June’08...
  • Page 71 Disconnect the high and low pressure pipes at the Hydraulic pump removing two socket head (if power steering fitted. Remove dual pump socket) cap screws on each connection. Fig. 2 C-15 35 Series 4WD, Model - 3535, 4035, 4535 and 5035 SM June’08...
  • Page 72 Insert the six bolts and lock washer and tighten up evenly. Withdraw the aligning tool. NOTE: It is recommend that new gaskets and O’Rings be used on installation. Fig. 4 C-16 35 Series 4WD, Model - 3535, 4035, 4535 and 5035 SM June’08...
  • Page 73 Fill the cooling system and check the air cleaner oil, engine oil, hydraulic oil, fuel and then bleed the diesel fuel system. C-17 35 Series 4WD, Model - 3535, 4035, 4535 and 5035 SM June’08...

  • Page 75: Manifolds, Cylinder Head & Valves

    CHAPTER - 2 MANIFOLDS, CYLINDER HEAD & VALVES 35 Series 4WD, Model - 3535, 4035, 4535 and 5035 SM June’08...
  • Page 77 Remove the manifold bolts & lift it off. Intake Manifold Exhaust Manifold Exhaust manifold can be removed by removing the four bolts (1-2). NOTE: In overall Engine Section, 3 cylinder pictures shown. Fig. 2 C-21 35 Series 4WD, Model - 3535, 4035, 4535 and 5035 SM June’08...
  • Page 78 Be sure all oil passages are free from sludge and sediment. Check the valve lever shaft expansion plugs. Check the clearance between the valve rocker arm shaft and valve rocker arm bushings. C-22 35 Series 4WD, Model - 3535, 4035, 4535 and 5035 SM June’08...
  • Page 79 Move each piston in the firing order to top dead center on the compression stroke. This can be ascertained by watching the valves of No.4 cylinder until intake valve just beginning to open and C-23 35 Series 4WD, Model - 3535, 4035, 4535 and 5035 SM June’08...
  • Page 80 3. To avoid warpage do not remove cylinder head bolts unless the engine has cooled down. C-24 35 Series 4WD, Model - 3535, 4035, 4535 and 5035 SM June’08...
  • Page 81 Check the diameter of the guides at several locknut 11. Valve spring seat points against the dimensions given in 6. Adjusting screw 12. Valve guide SPECIFICATIONS. 7. Rocker arm 13. Valve C-25 35 Series 4WD, Model - 3535, 4035, 4535 and 5035 SM June’08...
  • Page 82 26. Lock 27. Cup Camshaft 28. Spring Tappet 29. Washer 30. Set Rocker 31. Valve 10. Circlip 32. Valve 11. Washer Fig. 7 Fig. 9 Removing valves C-26 35 Series 4WD, Model - 3535, 4035, 4535 and 5035 SM June’08...
  • Page 83 Check and replace valve seals. Check the outside face and the ribs inside the collects for wear. It is advisable to always use new collets. Fig. 13 C-27 35 Series 4WD, Model - 3535, 4035, 4535 and 5035 SM June’08...
  • Page 84 ASSEMBLY : Install the push rods in their original position. Coat the valve stems with clean engine oil and install them in their original position. C-28 35 Series 4WD, Model - 3535, 4035, 4535 and 5035 SM June’08...
  • Page 85 While regrinding the valve maintain it’s concentricity with the guide to ensure proper seating. Never remove the cylinder head in hot condition. Fig. 15 The Guide Stud C-29 35 Series 4WD, Model - 3535, 4035, 4535 and 5035 SM June’08...

  • Page 87: Connecting Rods, Pistons & Cylinder Sleeves

    CHAPTER - 3 CONNECTING RODS, PISTONS & CYLINDER SLEEVES 35 Series 4WD, Model - 3535, 4035, 4535 and 5035 SM June’08...
  • Page 89 End Bush 4. Piston Check the pistons for seizure or/and overheating 11. Compression Ring 5. Pin marks. 12. Compression Ring 6. Circlip 13. Oil Ring 7. Connecting Rod C-33 35 Series 4WD, Model - 3535, 4035, 4535 and 5035 SM June’08...
  • Page 90 Remove each bearing cap and measure thickness of the plastigauge to determine the bearing clearance. Remove the connecting rod from the Fig. 4 crankshaft. Removing or installing piston pin circlips C-34 35 Series 4WD, Model - 3535, 4035, 4535 and 5035 SM June’08...
  • Page 91 Hold the piston and slowly pull the scale in a straight line with the ribbon, noting the pull required to remove the feeler ribbon. Do not bend or kink the ribbon gauge. C-35 35 Series 4WD, Model - 3535, 4035, 4535 and 5035 SM June’08...
  • Page 92 The connecting rod can be removed and installed 1. 1st compression ring 3. Oil control ring without having to separate the engine from the clutch. 2. 2nd compression ring 4. Insert C-36 35 Series 4WD, Model - 3535, 4035, 4535 and 5035 SM June’08...
  • Page 93 The cylinder sleeves should be renewed when out of round exceeds 0.20mm and taper exceeds 0.13mm. The old cylinder sleeve should be removed with the help of special service tool C-37 35 Series 4WD, Model - 3535, 4035, 4535 and 5035 SM June’08...
  • Page 94 Install the piston assemblies. Place the sleeve in the crankcase with out ‘O’ Ring. Clamp the sleeve down using four holding adapters/plate shown in fig.12 place sleeve holding plate locally. C-38 35 Series 4WD, Model - 3535, 4035, 4535 and 5035 SM June’08...
  • Page 95 0.076mm - 0.18mm above the cylinder block surface. Mark each sleeve before removing so that it can be reinstalled in the same bore and in the same position. C-39 35 Series 4WD, Model - 3535, 4035, 4535 and 5035 SM June’08...

  • Page 97: Lubrication Systems

    CHAPTER - 4 LUBRICATION SYSTEMS 35 Series 4WD, Model - 3535, 4035, 4535 and 5035 SM June’08...
  • Page 99 Check the oil pressure regulating valve spring (17-4) against the loads given in specifications. Check the oil pressure regulating valve (16-4) and seat for wear pitting or corrosion. Fig. 3 C-43 35 Series 4WD, Model - 3535, 4035, 4535 and 5035 SM June’08...
  • Page 100 Assemble the relief valve inside the pump body and install the spring. Tighten the retaining bolt using a new washer. C-44 35 Series 4WD, Model - 3535, 4035, 4535 and 5035 SM June’08...
  • Page 101 For new tractor and overhauled engine first service - Oil filter replacement after 200 hrs. It is highly detrimental to engine reliability, if cartridge is reused by reflushing with cleaning solvent. Dispose off immediately. C-45 35 Series 4WD, Model - 3535, 4035, 4535 and 5035 SM June’08...

  • Page 103: Timing Gear Train, Front Cover & Camshaft

    CHAPTER - 5 TIMING GEAR TRAIN, FRONT COVER & CAMSHAFT 35 Series 4WD, Model - 3535, 4035, 4535 and 5035 SM June’08...
  • Page 105 Press in a new oil seal with the lip facing inward until it is flush with the outside face of the front cover. INSTALLATION Reverse the removal procedure. C-49 35 Series 4WD, Model - 3535, 4035, 4535 and 5035 SM June’08...
  • Page 106 If inspection proves if necessary remove the thread insert and fit a new one. Fig. 2 Image is Representative C-50 35 Series 4WD, Model - 3535, 4035, 4535 and 5035 SM June’08...
  • Page 107 Withdraw the camshaft with gear from the crankcase. Remove the valve tappets (1-4) and identify them so they can be installed in their original positions. C-51 35 Series 4WD, Model - 3535, 4035, 4535 and 5035 SM June’08...
  • Page 108 Invert the engine and install the oil pump. Install the front cover. Install the valve push rods in their original positions. Install the valve rocker arm shaft assembly. C-52 35 Series 4WD, Model - 3535, 4035, 4535 and 5035 SM June’08...
  • Page 109 Secure the thrust plate to the crankcase with bolts and lock washers and tighten to the same specified torque. C-53 35 Series 4WD, Model - 3535, 4035, 4535 and 5035 SM June’08...

  • Page 111: Crankcase, Crankshaft, Main Bearings & Flywheel

    CHAPTER - 6 CRANKCASE, CRANKSHAFT, MAIN BEARINGS & FLYWHEEL 35 Series 4WD, Model - 3535, 4035, 4535 and 5035 SM June’08...
  • Page 113 Extreme care must be taken to assure perfect cleanliness of the crankcase, crankshaft and bearings after service has been completed. C-57 35 Series 4WD, Model - 3535, 4035, 4535 and 5035 SM June’08...
  • Page 114 If the surface is very rough take a fine cut with a lather tool before dressing the friction face with emery cloth. C-58 35 Series 4WD, Model - 3535, 4035, 4535 and 5035 SM June’08...
  • Page 115 Inspect the bearings for wear and evidence of uneven bearing support. If such evidence is present, examine the bearing caps and supporting surfaces of the crankcase for high spots and burrs. C-59 35 Series 4WD, Model - 3535, 4035, 4535 and 5035 SM June’08...
  • Page 116 These bearings are available in sets of +0.030” and +0.015”. See para. 3c for details of re-grinding crankshaft. C-60 35 Series 4WD, Model - 3535, 4035, 4535 and 5035 SM June’08...
  • Page 117 1.325 1.327 1.332 Permissible width of all Main Journal and Crank Pins except at No. 5 Journal ‘C’ listed above. Fig. 7 Undersize Limits for Crankshaft Regrinding C-61 35 Series 4WD, Model - 3535, 4035, 4535 and 5035 SM June’08...
  • Page 118 Improper running- in procedure may result in shorter engine life, loss of power and high oil consumption. C-62 35 Series 4WD, Model - 3535, 4035, 4535 and 5035 SM June’08...
  • Page 119 Ensure that inserts are driven into the the specified torque. specified depth. C-63 35 Series 4WD, Model - 3535, 4035, 4535 and 5035 SM June’08...
  • Page 120 If FIP mounting Studs are to be replaced, apply Loctite 577 to FIP mounting Studs & fix the same in Adapter Torque the studs to 15-16 Lb. ft. Fuel Timing Adjustment C-64 35 Series 4WD, Model - 3535, 4035, 4535 and 5035 SM June’08...
  • Page 121 Inspect port and connectors to ensure that threads on both are free of dirt, burrs and excessive nicks. C-65 35 Series 4WD, Model - 3535, 4035, 4535 and 5035 SM June’08...
  • Page 122 If port threads are damaged, re-tap, if possible, or replace the component. If the port is cracked, replace the component. C-66 35 Series 4WD, Model - 3535, 4035, 4535 and 5035 SM June’08...
  • Page 123 Only then can you expect ready and efficient performance and trouble-free operation the year round. C-67 35 Series 4WD, Model - 3535, 4035, 4535 and 5035 SM June’08...

  • Page 125: Special Notes & Trouble Shooting

    CHAPTER - 7 SPECIAL NOTES & TROUBLE SHOOTING 35 Series 4WD, Model - 3535, 4035, 4535 and 5035 SM June’08...
  • Page 127 If the compression is low on one Bring the electrolyte up to full with distilled or more cylinders, make the necessary repairs. water. If only one cylinder is low, squirt some engine C-71 35 Series 4WD, Model - 3535, 4035, 4535 and 5035 SM June’08...
  • Page 128 11. Lack of compression - - - - - - - - - - - - - - - - - - - - - Refer to “Poor Compression” C-72 35 Series 4WD, Model - 3535, 4035, 4535 and 5035 SM June’08...
  • Page 129 14. Cylinder head gasket/leaking - - - - - - - - - - - - - - - Install new head gasket properly using sealing compound. C-73 35 Series 4WD, Model - 3535, 4035, 4535 and 5035 SM June’08...
  • Page 130 - - - - - - - - - - - - - - - - - - - - - Readjust Valve and spring assembly in operative - - - - - - - Repair and install parts needed. C-74 35 Series 4WD, Model - 3535, 4035, 4535 and 5035 SM June’08...
  • Page 131 - - - - - - - - - - - - - - - - - - - - - - - - Ream valve guides for proper clearance. C-75 35 Series 4WD, Model - 3535, 4035, 4535 and 5035 SM June’08...
  • Page 132 Improper grade of fuel - - - - - - - - - - - - - - - - - - - Use correct fuel Air leaks on suction side of injection pump - - - - Tighten fuel lines. Check for defective fuel filter case gaskets. C-76 35 Series 4WD, Model - 3535, 4035, 4535 and 5035 SM June’08...

  • Page 133: Cooling System

    CHAPTER - 8 COOLING SYSTEM 35 Series 4WD, Model - 3535, 4035, 4535 and 5035 SM June’08...
  • Page 135 60/40 Freeze Protection Boil over protection +265 +275 (with 15 psi radiator cap) Recommended change period : 1 year or when ever the radiator water is drained. C-79 35 Series 4WD, Model - 3535, 4035, 4535 and 5035 SM June’08...
  • Page 136 Tractor. This cycle is repeated to keep the Engine at a desired optimum/ working temperature. C-80 35 Series 4WD, Model - 3535, 4035, 4535 and 5035 SM June’08...
  • Page 137 C. Adjusting Bolt D. Adjusting Bracket Remove the fan housing from the radiator. C-81 35 Series 4WD, Model - 3535, 4035, 4535 and 5035 SM June’08...
  • Page 138 Flush the Radiator with clean water. Flushing the Radiator : Thoroughly flush inside of the Radiator using good clean water. The outside of the Core should be flushed well C-82 35 Series 4WD, Model - 3535, 4035, 4535 and 5035 SM June’08...
  • Page 139 Remove the vertical exhaust silencer, blades. precleaner and raise hood. Remove the six round headed capscrews Remove the fan (Refer to para.5 REMOVAL). (6-4) and their washers and nuts which secure C-83 35 Series 4WD, Model - 3535, 4035, 4535 and 5035 SM June’08...
  • Page 140 Loosen the clamps on the radiator upper hose and work the hose clear of the thermostat housing. Remove the three capscrews (1-12) from the thermostat housing (2-12) and withdraw the thermostat. C-84 35 Series 4WD, Model - 3535, 4035, 4535 and 5035 SM June’08...
  • Page 141 Screw Driver. All new Hoses and their connection should be checked a couple of times subsequent to fitting. After the Engine has been in use, retighten all connections, as necessary. C-85 35 Series 4WD, Model - 3535, 4035, 4535 and 5035 SM June’08...
  • Page 142 Dirty, Scad Coolant passages. Clean & flush passages. 10. Radiator Togged. 10. Flush out radiator. 11. Fan Roll Slippage. 11. Check the tension; replace, it greasy or worn. C-86 35 Series 4WD, Model - 3535, 4035, 4535 and 5035 SM June’08...

  • Page 143: Air Cleaner

    CHAPTER - 9 AIR CLEANER 35 Series 4WD, Model - 3535, 4035, 4535 and 5035 SM June’08...
  • Page 145 Loosen the hose clips (A) of hose (B). Loosen the wing nut (C) & turn the clamp (D). Disconnect the Air Cleaner Clog Indicator Sensor wiring connections. Take out air cleaner. C-89 35 Series 4WD, Model - 3535, 4035, 4535 and 5035 SM June’08...
  • Page 146 If Secondary Element is replaced, install new element immediately to prevent dust from entering air intake system. Primary Element Filter Replace Secondary Element (J), if dirty or damaged. Safety Cartridge C-90 35 Series 4WD, Model - 3535, 4035, 4535 and 5035 SM June’08...
  • Page 147 G. STORING ELEMENT If element is not installed on tractor, seal element in a plastic bag and store in its original shipping container to protect against dust and damage. C-91 35 Series 4WD, Model - 3535, 4035, 4535 and 5035 SM June’08...
  • Page 148 / Serviced. After servicing, reset the clog indicator by pressing rubber cap. (As marked in the figure). Ensure red band will move to the original position after resetting. C-92 35 Series 4WD, Model - 3535, 4035, 4535 and 5035 SM June’08...

  • Page 149: Fuel System

    CHAPTER - 10 FUEL SYSTEM 35 Series 4WD, Model - 3535, 4035, 4535 and 5035 SM June’08...
  • Page 151 Raise the hood, and disconnect the battery. Remove the battery. Remove the scuttle panel and the filler plate. Fig.1 Left Hand view of Engine 1. Fuel Filter 2. Rotary Pump 3. Starter Motor C-95 35 Series 4WD, Model - 3535, 4035, 4535 and 5035 SM June’08...
  • Page 152 Remove the fuel cock and blow with compressed air to clean it. Replace it after cleaning and check for any leakage. Fig.2 C-96 35 Series 4WD, Model - 3535, 4035, 4535 and 5035 SM June’08...
  • Page 153 30 seconds. Always close the air vent screw except for bleeding fuel lines other wise, engine will run irregularly or stall frequently. C-97 35 Series 4WD, Model - 3535, 4035, 4535 and 5035 SM June’08...
  • Page 154 - injection will lead to coking and will affect atomization and induce on irregular exhaust beat. Nozzle coking can also disturb spray from the prescribed directions. C-98 35 Series 4WD, Model - 3535, 4035, 4535 and 5035 SM June’08...
  • Page 155 8. Cylinder Block 16. Gasket Wipe off dirt and loose carbon from each injector with a cloth and clean the tip with a brass wire brush. C-99 35 Series 4WD, Model - 3535, 4035, 4535 and 5035 SM June’08...
  • Page 156 1.7 to 2.3 mm is to be ensured. The cross sectional view of the engine showing the nozzle tip protrusion is show in fig.6. C-100 35 Series 4WD, Model - 3535, 4035, 4535 and 5035 SM June’08...
  • Page 157 It is switch “OFF” after 20 minutes restoring the normal timing. The KSB timer relay is switch “ON” everytime the tractor is switch “ON” from “OFF” condition. C-101 35 Series 4WD, Model - 3535, 4035, 4535 and 5035 SM June’08...
  • Page 158 Injection Timing (mm@tdc) For 3 Cyl. For 4 Cyl. For 4035 / 3535 — 0.95 ± 0.02 mm For 4535 / 5035 — 1.00 ± 0.02 mm Fig. 6 C-102 35 Series 4WD, Model - 3535, 4035, 4535 and 5035 SM June’08...
  • Page 159 BOSCH dealer in undisturbed condition, IKSB should be in undisturbed condition. IKSB unit of one pump should in no circumstance be replaced on another pump without calibration of the pump. C-103 35 Series 4WD, Model - 3535, 4035, 4535 and 5035 SM June’08...
  • Page 160 Fuel System Fuel Injection Pump Calibration Chart - 3535 C-104 35 Series 4WD, Model - 3535, 4035, 4535 and 5035 SM June’08...
  • Page 161 Fuel System Fuel Injection Pump Calibration Chart - 3535 C-105 35 Series 4WD, Model - 3535, 4035, 4535 and 5035 SM June’08...
  • Page 162 Fuel System Fuel Injection Pump Calibration Chart - 4035 C-106 35 Series 4WD, Model - 3535, 4035, 4535 and 5035 SM June’08...
  • Page 163 Fuel System Fuel Injection Pump Calibration Chart - 4035 C-107 35 Series 4WD, Model - 3535, 4035, 4535 and 5035 SM June’08...
  • Page 164 Fuel System Fuel Injection Pump Calibration Chart - 4535 C-108 35 Series 4WD, Model - 3535, 4035, 4535 and 5035 SM June’08...
  • Page 165 Fuel System Fuel Injection Pump Calibration Chart - 4535 C-109 35 Series 4WD, Model - 3535, 4035, 4535 and 5035 SM June’08...
  • Page 166 Fuel System Fuel Injection Pump Calibration Chart - 5035 C-110 35 Series 4WD, Model - 3535, 4035, 4535 and 5035 SM June’08...
  • Page 167 Fuel System Fuel Injection Pump Calibration Chart - 5035 C-111 35 Series 4WD, Model - 3535, 4035, 4535 and 5035 SM June’08...

  • Page 168: Group-D

    Group-D C l u t c h Clutch ................D1 – D10 35 Series 4WD, Model - 3535, 4035, 4535 and 5035 SM June’08...
  • Page 170 1.6 to 1.8 inch TORQUE Clutch release fork bolt 41 - 50 Nm (30 - 37 lb.ft.) Clutch assy. mounting bolt 21 - 25 Nm (15 - 18 lb.ft.) 35 Series 4WD, Model - 3535, 4035, 4535 and 5035 SM June’08...
  • Page 171 Place a guide shaft tool (C) during assembly of PTO damper. Fit PTO damper (D). Slide the clutch plate (E). Fit the clutch assembly (F) and tighten mounting bolts and remove guide shaft tool (C). 35 Series 4WD, Model - 3535, 4035, 4535 and 5035 SM June’08...
  • Page 172 Pierce out (by drilling) cover rivets and remove pressure plate sub assembly. Then gently pierce out (by drilling) delta rivet Fig. 3 riveted head and remove diaphragm. 35 Series 4WD, Model - 3535, 4035, 4535 and 5035 SM June’08...
  • Page 173 Check the vibration dampener springs of the driven members and see if they are loose or broken or have taken a set through heat. If any doubt exists, replace the driven member. 35 Series 4WD, Model - 3535, 4035, 4535 and 5035 SM June’08...
  • Page 174 Assembly of diaphragm Place the diaphragm over the fixture as shown in the fig.6. Slots in the diaphragm should passes through the delta rivet. 35 Series 4WD, Model - 3535, 4035, 4535 and 5035 SM June’08...
  • Page 175 Unscrew the alignment screws and take out pressure plate sub. assy. NOTE: Drive strap should not rotate freely after riveting. Riveted (formed) head diameter should be 10 to 11 mm. Fig. 9 Fig. 10 35 Series 4WD, Model - 3535, 4035, 4535 and 5035 SM June’08...
  • Page 176 Withdraw the pilot tool. Installation is now the reversal of the “REMOVAL” procedure. Fig. 14 35 Series 4WD, Model - 3535, 4035, 4535 and 5035 SM June’08...
  • Page 177 (3) Steering Mechanism (3) Refer to 'Steering Faulty Mechanism' Section (4) Binding in Differential Remove, Disassemble and inspect (5) Uneven Tire Inflation (5) Check Tire Pressure Pressure D-10 35 Series 4WD, Model - 3535, 4035, 4535 and 5035 SM June’08...

  • Page 178: Group-E

    Differential ..............E31 – E44 Differential Lock System ..........E45 – E50 Rear PTO Cover ............. E51 – E54 Wet Clutch PTO ............E55 – E58 Brakes ................E59 – E65 35 Series 4WD, Model - 3535, 4035, 4535 and 5035 SM June’08...

  • Page 180: Transmission

    CHAPTER - 1 TRANSMISSION 35 Series 4WD, Model - 3535, 4035, 4535 and 5035 SM June’08...
  • Page 182 & speed bearing front 1st Gear Between speed countershaft rear 0.004” 0.008” Graded Shim bearing & circlip Between 4WD Idler Gear & the washer 0.011” 0.016” Graded Washer Front 35 Series 4WD, Model - 3535, 4035, 4535 and 5035 SM June’08...
  • Page 183 Clutch Housing To Transmission Case Hex. Flange Bolt M14 x 1.5 x 40L Clutch Housing To Transmission Case Stud M14 x 50 Clutch Housing To Transmission Case Flange Nut M14 x 1.5 35 Series 4WD, Model - 3535, 4035, 4535 and 5035 SM June’08...
  • Page 184 Bolt M8 x 1.25 x 22 Suction Strainer PTO Control Valve Mounting Bolt M10 x 1.5 x 20 Rear Cover Transmission Case Pipe Coupling 1/4” BSP Rear Cover Transmission Case Banjo Body M18x1.5 35 Series 4WD, Model - 3535, 4035, 4535 and 5035 SM June’08...
  • Page 185 6. Differential Lock • Differential lock shaft spring weaken or • Replace Pedal does not damaged return • Differential shift/lock ring pin damaged • Replace 35 Series 4WD, Model - 3535, 4035, 4535 and 5035 SM June’08...
  • Page 186 FORWARD / REVERSE Major Components Engine Flywheel Clutch Assembly Transmission Drive Shaft P.T.O. Drive Shaft Speed Driving Shaft Forward - Reverse Synchronizer Forward Gear - Driven Reverse Gear - Driven 35 Series 4WD, Model - 3535, 4035, 4535 and 5035 SM June’08...
  • Page 187 Reverse Gear (F) and then to Synchroniser (D) to Counter Speed Driving Shaft Shaft (J). Forward - Reverse Synchronizer Forward Gear Driven Reverse Gear Driven Forward Gear Driving Reverse Gear Driving Reverse Idler Gear Counter Shaft E-10 35 Series 4WD, Model - 3535, 4035, 4535 and 5035 SM June’08...
  • Page 188 The power from Engine via forward and reverse gear rotates the Counter Shaft (J) and 1st - 2nd Synchronizer (L). It equalizes the speed of the involved shafts before the shifting ring engage. E-11 35 Series 4WD, Model - 3535, 4035, 4535 and 5035 SM June’08...
  • Page 189 (T) to 4th Driven Gear (V) on Speed Shaft (C) to the Synchronizer (R) splined with the Speed Shaft. Hence power goes to Range Shaft (Q) through coupling (K). E-12 35 Series 4WD, Model - 3535, 4035, 4535 and 5035 SM June’08...
  • Page 190 Shift Coupling Engaged with high gear The power from Range Shaft high driving gear (A) flows to high driven gear (B) through coupling (C) to the spline shaft (D) and splined collar. E-13 35 Series 4WD, Model - 3535, 4035, 4535 and 5035 SM June’08...
  • Page 191 Shift Coupling Engaged with Low gear The power from Range Shaft low driving gear (H) flows to low driven gear (I) through Coupling (C) to the spline shaft (D). E-14 35 Series 4WD, Model - 3535, 4035, 4535 and 5035 SM June’08...
  • Page 192 Remove PTO input shaft, remove transmission driving hollow shaft along with front bearing. Hold the gears and spacers in position. Remove gears and spacers. Remove top cover (E) by loosening bolt (F). E-15 35 Series 4WD, Model - 3535, 4035, 4535 and 5035 SM June’08...
  • Page 193 (L) by using special tool. Remove speed rail detention bolt, springs and balls, remove forks and rails. Remove middle wall ball bearing by removing circlip top shaft. E-16 35 Series 4WD, Model - 3535, 4035, 4535 and 5035 SM June’08...
  • Page 194 Remove all gasket material from joint face. Inspect bushes for wear or damage, worn chipped or broken teeth check splines for correct fit. Check excessive play. E-17 35 Series 4WD, Model - 3535, 4035, 4535 and 5035 SM June’08...
  • Page 195 Assemble shuttle shift fork after counter shaft assembly. Install forward / reverse and speed levers and then arms. Fit the oil seals by using sleeve. Check float. E-18 35 Series 4WD, Model - 3535, 4035, 4535 and 5035 SM June’08...
  • Page 196 Check centralization of fork by dial gauge shifting in forward and reverse direction. If required adjust the centralization putting remaining shims at countershaft rear end bearing. Keeping dummy piece of front retainer. E-19 35 Series 4WD, Model - 3535, 4035, 4535 and 5035 SM June’08...
  • Page 197 540 input shaft and gear assembly. Remove external circlip inside hub and remove hub. Remove PTO middle support bearing rear circlip. Remove PTO intermediate shaft with ball bearing from rear side. E-20 35 Series 4WD, Model - 3535, 4035, 4535 and 5035 SM June’08...
  • Page 198 Assemble shifter arm in fork slot. Insert cross shaft and lock the arm with roll pin with cross shaft. E-21 35 Series 4WD, Model - 3535, 4035, 4535 and 5035 SM June’08...
  • Page 199 Check backlash of gear, locking collar and output shaft. If it is more than limit, replace it. Assembly Assemble the removed parts in the reverse sequence of dismantling. E-22 35 Series 4WD, Model - 3535, 4035, 4535 and 5035 SM June’08...

  • Page 200: Rear Axle

    CHAPTER - 2 REAR AXLE 35 Series 4WD, Model - 3535, 4035, 4535 and 5035 SM June’08...
  • Page 202 Rear Axle Sub Assembly LH Rear Axle Bearing Retainer Bull Shaft Bull Gear LH Ball Bearing Carrier Differential RH Bevel Gear Differential LH Oil Seal Coupling Differential Lock E-25 35 Series 4WD, Model - 3535, 4035, 4535 and 5035 SM June’08...
  • Page 203 Disconnect the wiring harness from couplers. Removal of Tires Remove ROPS, by removing ROPS Mounting Bracket Assembly. Removal of ROPS Remove fender mounting bolts. Removal of Fenders E-26 35 Series 4WD, Model - 3535, 4035, 4535 and 5035 SM June’08...
  • Page 204 (as shown in fig.). Remove bull gear (B). Tap the rear axle splined end with copper hammer and pull out the rear axle from other end. E-27 35 Series 4WD, Model - 3535, 4035, 4535 and 5035 SM June’08...
  • Page 205 Check splines for burrs and correct fitting. Check bull pinion shaft for damage, pitting and burrs and backlash. Check Ball Bearings and oil seals for damages and pitting, if require replace it. E-28 35 Series 4WD, Model - 3535, 4035, 4535 and 5035 SM June’08...
  • Page 206 Rear Axle (2 nos.). Install oil seals with retainer in Rear Axle. Install outer ball bearing with fixture for positioning of bearing. Apply liquid gasket on retainer. E-29 35 Series 4WD, Model - 3535, 4035, 4535 and 5035 SM June’08...
  • Page 207 Assemble washer, lock plate and bull gear retaining bolt. Torque them to 265 - 290 Nm. Ensure free movement by rotating rear axle carrier. E-30 35 Series 4WD, Model - 3535, 4035, 4535 and 5035 SM June’08...

  • Page 208: Differential

    CHAPTER - 3 DIFFERENTIAL 35 Series 4WD, Model - 3535, 4035, 4535 and 5035 SM June’08...
  • Page 210 When tractor takes a turn, one axle moves faster than other. This results in rotation of differential pinion to rotate on it’s own axis, and they roll over bevel gear and thus producing differential action. E-33 35 Series 4WD, Model - 3535, 4035, 4535 and 5035 SM June’08...
  • Page 211 The differential gear assembly is a mechanism to provide smooth steering. It automatically provides relative speed to both rear wheels according to road resistance and braking friction at the wheel. E-34 35 Series 4WD, Model - 3535, 4035, 4535 and 5035 SM June’08...
  • Page 212 Remove retainer (A) alongwith differential housing assembly by loosening bolt (B). Tap slightly, o take out the differential assembly (C) complete. NOTE: Remove differential lock shifting arrangement before dismantling differential case assembly. E-35 35 Series 4WD, Model - 3535, 4035, 4535 and 5035 SM June’08...
  • Page 213 Remove the taper roller bearing (A) and withdraw differential lock coupling (B). Remove Ring Gear (C) by loosening bolts (D). Remove spring pin (E) by using Special Tool (F). E-36 35 Series 4WD, Model - 3535, 4035, 4535 and 5035 SM June’08...
  • Page 214 Check the ring gear for wear and damage. If no longer serviceable, replace it with spiral pinion shaft as a set. Check Taper Roller Bearings for wear, pitting or crack. If necessary replace it. E-37 35 Series 4WD, Model - 3535, 4035, 4535 and 5035 SM June’08...
  • Page 215 NOTE : Check preload without spiral gear pinion. After preloading check the backlash. Install rear axle as detailed in “Rear Axle”. Install PTO housing assembly. Fill the oil. Checking Preload E-38 35 Series 4WD, Model - 3535, 4035, 4535 and 5035 SM June’08...
  • Page 216 Check the preload with string and spring balance. Adjust graded spacer if required to achieve specified bearing preload. E-39 35 Series 4WD, Model - 3535, 4035, 4535 and 5035 SM June’08...
  • Page 217 5. After Preloading, remove differential case assembly with shims and fit after preloading the spline shaft. E-40 35 Series 4WD, Model - 3535, 4035, 4535 and 5035 SM June’08...
  • Page 218 If it is necessary to reset the pinion, the backlash will Fig. C Fig. D need to be adjusted. Fig. E Fig. F E-41 35 Series 4WD, Model - 3535, 4035, 4535 and 5035 SM June’08...
  • Page 219 0.2" - 0.008" = 0.1992". NOTE: The average thickness of the spacer is 0.203" and graded spacers are available in thickness range of 0.192" to 0.214" in increment of 0.001". E-42 35 Series 4WD, Model - 3535, 4035, 4535 and 5035 SM June’08...
  • Page 220 Recheck the mounting distance. During cone center adjustment it is imperative that backlash be present. Ring Gear 4.4 - 6.6 lbs. Differential Case Preload Spline Shaft 5.7 - 8.15 lbs. E-43 35 Series 4WD, Model - 3535, 4035, 4535 and 5035 SM June’08...
  • Page 221 Bevel Gear Differential RH Differential Case Bull Gear Bull Pinion Brake Shaft LH Bull Pinion Brake Shaft RH Bevel Gear Differential LH Rear Axle Gear Crown Wheel Differential Housing Assembly E-44 35 Series 4WD, Model - 3535, 4035, 4535 and 5035 SM June’08...

  • Page 222: Differential Lock System

    CHAPTER - 4 DIFFERENTIAL LOCK SYSTEM 35 Series 4WD, Model - 3535, 4035, 4535 and 5035 SM June’08...
  • Page 224 Since the bull pinion shaft is coupled with spline bevel gear, no differential action takes place and both bull pinion shaft rotate with equal RPM. E-47 35 Series 4WD, Model - 3535, 4035, 4535 and 5035 SM June’08...
  • Page 225 Remove fork spring lock pin (D). Special Tool Removal of Differential Lock Shaft Pin Hold spring and differential lock fork and pull differential cross shaft from RH side. E-48 35 Series 4WD, Model - 3535, 4035, 4535 and 5035 SM June’08...
  • Page 226 Insert spring dowel near fork. Insert washer and spring dowel at LH side. Installation Installation is reverse procedure of Removal. Assembling Differential Lock Shaft Assembly with Fork E-49 35 Series 4WD, Model - 3535, 4035, 4535 and 5035 SM June’08...

  • Page 228: Rear Pto Cover

    CHAPTER - 5 REAR PTO COVER 35 Series 4WD, Model - 3535, 4035, 4535 and 5035 SM June’08...
  • Page 230 After assembly, check smooth rotation of wet Assembling Rear PTO Cover clutch. Then clamp the mounting bolts to the specified torque values. E-53 35 Series 4WD, Model - 3535, 4035, 4535 and 5035 SM June’08...

  • Page 232: Wet Clutch Pto

    CHAPTER - 6 WET CLUTCH PTO 35 Series 4WD, Model - 3535, 4035, 4535 and 5035 SM June’08...
  • Page 234 Hold the Output gear in position with input gear. Push output shaft in out put gear with spacer in position and insert in bearing and oil seal. Output Shaft E-57 35 Series 4WD, Model - 3535, 4035, 4535 and 5035 SM June’08...
  • Page 235 NOTE: Ensure that the brake lug of wet clutch is properly seated into the stopper provided on transmission case. E-58 35 Series 4WD, Model - 3535, 4035, 4535 and 5035 SM June’08...

  • Page 236: Brakes

    CHAPTER - 7 BRAKES 35 Series 4WD, Model - 3535, 4035, 4535 and 5035 SM June’08...
  • Page 238 • Brake lever and shaft damaged • Replace • Transmission oil improper • Change 4. Brake Noisy • Wrong grad oil • Change • Contaminated oil with water • Change E-61 35 Series 4WD, Model - 3535, 4035, 4535 and 5035 SM June’08...
  • Page 239 Cover Plate and Rear Axle Carrier Housing. Friction Plate get compressed between adjacent mating surface, so frictional force is generated and this force stops the rotation of Bull Shaft. Thus Brakes are applied. E-62 35 Series 4WD, Model - 3535, 4035, 4535 and 5035 SM June’08...
  • Page 240 50 hrs. or 80 hrs., Almost no wear occurs afterwards. This means that very little wear adjustments are required. Since the brake disc are immersed in transmission oil ‘Fade’ is rarely caused. E-63 35 Series 4WD, Model - 3535, 4035, 4535 and 5035 SM June’08...
  • Page 241 Remove retainer (F) from other side by loosening the bolts (G). Take out bull shaft (H) with bearing (I) by slight tapping. Removal of Bull Pinion Brake Shaft E-64 35 Series 4WD, Model - 3535, 4035, 4535 and 5035 SM June’08...
  • Page 242 Installation Reverse procedure of removal and dismantling. Tighten the bolts at specified torque and check all friction plates and disc intermediates are free. E-65 35 Series 4WD, Model - 3535, 4035, 4535 and 5035 SM June’08...

  • Page 244: Group-F

    Group-F F r o n t A x l e Front Axle ..............F1 – F25 35 Series 4WD, Model - 3535, 4035, 4535 and 5035 SM June’08...
  • Page 246 2. Oil Filling and Level Check Point LH 5. Oil Drain Plug Swivel Housing RH 3. Oil Drain Plug Differential Housing Lubrication / Greasing : Grades & Application Range 35 Series 4WD, Model - 3535, 4035, 4535 and 5035 SM June’08...
  • Page 247 Incorrect adjustment of bevel gear set: Parts a few meters away only. of the transmission worn out. (Transmission gears, U joints, etc.) Bent halfshaft Replace or adjust as required. Replace halfshaft. 35 Series 4WD, Model - 3535, 4035, 4535 and 5035 SM June’08...
  • Page 248 Use correct lubrication fill up, to 2. Contaminated oil the right level and replace at 3. Excessive use recommended intervals 4. Normal wear out 5. Pinion nut loosened 35 Series 4WD, Model - 3535, 4035, 4535 and 5035 SM June’08...
  • Page 249 Replace halfshaft overloaded Replace Halfshaft broken 1. Wheel support loosened at wheel side Check that wheel support is not 2. Beam body bent worn out or wrongly adjusted. 35 Series 4WD, Model - 3535, 4035, 4535 and 5035 SM June’08...
  • Page 250 1. Replace steering 2. Worn out differential box or spider 2. Replace 3. Differential thrust washers worn out 3. Replace 4. Half shaft spline worn out 4. Replace 35 Series 4WD, Model - 3535, 4035, 4535 and 5035 SM June’08...
  • Page 251 To Hub Housing Power Cylinder To Beam Housing Bolt M14 x 1.5 x 33 Tie Rod Ball Joint Assembly Bolt M18 x 1 Nylock nut To Top Cover 35 Series 4WD, Model - 3535, 4035, 4535 and 5035 SM June’08...
  • Page 252 Rear Standard Values as ø 70 ø 74 assembled (mm) Usable limit (mm) ø 70.2 ø 74.2 Worn or damaged oil seals, O’rings, bearings, etc. should be replaced. 35 Series 4WD, Model - 3535, 4035, 4535 and 5035 SM June’08...
  • Page 253 Remove intermediate bevel gear with bearing through slot provided. NOTE: Inspect the gear and spline for damage. F-10 35 Series 4WD, Model - 3535, 4035, 4535 and 5035 SM June’08...
  • Page 254 Check all pinion components for wear and damage. Number of shims and thickness to be noted down for both side and preserve it for assembly. F-11 35 Series 4WD, Model - 3535, 4035, 4535 and 5035 SM June’08...
  • Page 255 25 Nm. Put spacer (E) in another side of hub housing. Place a spindle axle (F) on fixture and put O’ring (G) on the flange. F-12 35 Series 4WD, Model - 3535, 4035, 4535 and 5035 SM June’08...
  • Page 256 (65 Nm). Lock the bolt by bending washer (J) at three places near bolt head. Fit O’ring (K) in place. NOTE: Apply oil to O’ring before fitment. F-13 35 Series 4WD, Model - 3535, 4035, 4535 and 5035 SM June’08...
  • Page 257 55-65 Nm. Fit the allen bolt (G) with copper washer. NOTE: During oil filling in swivel housing, remove the allen bolt and fit after oil filling. F-14 35 Series 4WD, Model - 3535, 4035, 4535 and 5035 SM June’08...
  • Page 258 (C). Adjust nut till desired backlash and crimp (D) the special nut. Check the backlash, it should be between 0.13 to 0.20 mm. Fit the oil seal (E). F-15 35 Series 4WD, Model - 3535, 4035, 4535 and 5035 SM June’08...
  • Page 259 Fit the cover (D) on swivel housing and tighten bolts (E) to torque 65-72 Nm. Check backlash for final reduction gear pair, it should be between 0.13 to 0.30 mm., if necessary adjust the shims. F-16 35 Series 4WD, Model - 3535, 4035, 4535 and 5035 SM June’08...
  • Page 260 Fit top cover to side housing by slight tapping and tighten the mounting bolt to specified torque (70-80 Nm) and tighten the nut to torque 110 Nm. F-17 35 Series 4WD, Model - 3535, 4035, 4535 and 5035 SM June’08...
  • Page 261 Press the outer cone of bearing to both side of housing input shaft. Put shims (D) and spacer (E) on pinion. Insert housing input shaft to the pinion. F-18 35 Series 4WD, Model - 3535, 4035, 4535 and 5035 SM June’08...
  • Page 262 Finally crimp the lock washer in pinion slot provided. Preload after oil seal fitment to be 4 to 5 Kg. NOTE: Preload to be measured before oil seal fitment. F-19 35 Series 4WD, Model - 3535, 4035, 4535 and 5035 SM June’08...
  • Page 263 (F) with proper dolly. Assemble differential case LH (G) along with thrust washer (H) and differential gear (I). Assemble differential case LH and RH with position mark as supplied. F-20 35 Series 4WD, Model - 3535, 4035, 4535 and 5035 SM June’08...
  • Page 264 NOTE: The taper roller bearings and cups / cones are not serviceable separately. Ensure to assemble new match pair while repairing. Hold the housing differential carrier (O) on suitable fixture and place differential assembly. F-21 35 Series 4WD, Model - 3535, 4035, 4535 and 5035 SM June’08...
  • Page 265 Check the differential gear backlash as specified. Backlash Differential gear - 0.1 to 0.25 mm. Adjust the backlash by shifting shims (Q) from one side to other. F-22 35 Series 4WD, Model - 3535, 4035, 4535 and 5035 SM June’08...
  • Page 266 Put spacer (D) to beam housing both end side. (Not Applicable for 29 PTO). NOTE: This spacer applicable 29 PTO tractors. Fit side housing to beam housing with the help of suitable hoist. F-23 35 Series 4WD, Model - 3535, 4035, 4535 and 5035 SM June’08...
  • Page 267 Then tighten pillow block bolt to stop the swinging action of axle. Loose the same bolt for only half rotation and tighten the nut to get float. F-24 35 Series 4WD, Model - 3535, 4035, 4535 and 5035 SM June’08...
  • Page 268 19. Swivel Housing LH 29. O’Ring 39. Cover Swivel Housing Bottom 49. Shaft Beam Housing 10. Hex. Bolt 20. Drain Plug 30. Top Cover RH 40. Swivel Housing RH F-25 35 Series 4WD, Model - 3535, 4035, 4535 and 5035 SM June’08...

  • Page 269: Group-G

    Group-G E l e c t r i c a l Electrical System ............G1 – G28 35 Series 4WD, Model - 3535, 4035, 4535 and 5035 SM June’08...

  • Page 271: Electrical System

    7. Broken or defective wiring. 7. Check wiring and make connections. 2. Alternator 1. Internal short. 1. Inspect and repair output excessive alternator. 2. Voltage regulator defective. 2. Replace regulator. 35 Series 4WD, Model - 3535, 4035, 4535 and 5035 SM June’08...
  • Page 272 Rotor open circuit Check that the ends of the rotor winding are soldered properly to slipring terminals. Re solder the windings if open or replace the rotor. 35 Series 4WD, Model - 3535, 4035, 4535 and 5035 SM June’08...
  • Page 273 8. Repair or replace 9. Main switch defective. 9. Replace 10.Starter motor pilot switch out 10.Replace or readjust of adjustment or defective. switch. 11.Starter motor solenoid switch 11.Replace switch. defective. 35 Series 4WD, Model - 3535, 4035, 4535 and 5035 SM June’08...
  • Page 274 6. Engine does not start 3. Starter relay defective. PTO • Replace relay / PTO flasher & Neutral switch defective 4. Wiring disconnected / loose Tighten properly connected 35 Series 4WD, Model - 3535, 4035, 4535 and 5035 SM June’08...
  • Page 275 12. Parking brake indicator does 2. Brake switch defective (Pork) Replace not function 3. Wiring harness disconnected Repair or Replace from switch and panel. 4. Instrumental cluster Replace defective 35 Series 4WD, Model - 3535, 4035, 4535 and 5035 SM June’08...
  • Page 276 1. Blown bulb Replace not working 2. Main brake switch faulty Replace 3. Parking brake switch faulty Replace 4. Wiring Harness loosen or Rectify the problem wrongly connection. 35 Series 4WD, Model - 3535, 4035, 4535 and 5035 SM June’08...
  • Page 277 2. KSB Relay faulty Replace 3. Wiring faulty Rectify or Replace NOTE: If heater indicator is “ON” for more than 2 minutes, switch “OFF” the tractor and remove the battery connection. 35 Series 4WD, Model - 3535, 4035, 4535 and 5035 SM June’08...
  • Page 278 10. 4WD Indicator controls regardless of experience, must read operators manual carefully before attempting 11. Parking Brake Indicator to operate the tractor. 12. Heater Indicator G-10 35 Series 4WD, Model - 3535, 4035, 4535 and 5035 SM June’08...
  • Page 279 When the pointer lies in RED band : 1. Indicates excessive engine coolant temperature. 2. Get the cause identified. 3. Further engine operation should be done only after elimination of the problem. G-11 35 Series 4WD, Model - 3535, 4035, 4535 and 5035 SM June’08...
  • Page 280 Engine is running and healthy it should be in GREEN Zone. If the pointer is in RED Zone, the problem should be eliminated before starting the engine. G-12 35 Series 4WD, Model - 3535, 4035, 4535 and 5035 SM June’08...
  • Page 281 LH side of steering column on dashboard. ON position operates LH, RH turn signal lamps simultaneously. This operation can be performed even if the key switch is in OFF position. G-13 35 Series 4WD, Model - 3535, 4035, 4535 and 5035 SM June’08...
  • Page 282 It is a 2 positions rotary switch located in LH side of steering column on dashboard. It operates in clockwise direction and positions are as follows: 1. Off 2. Illuminates the plow lamp G-14 35 Series 4WD, Model - 3535, 4035, 4535 and 5035 SM June’08...
  • Page 283 While this switch is in AUTO-POSITION and the clutch pedal is pressed, the PTO shaft rotation will be stopped and indicated by A BLINKING “PTO Engage - Disengage Switch” G-15 35 Series 4WD, Model - 3535, 4035, 4535 and 5035 SM June’08...
  • Page 284 Auto Mode Pressed Either raised Blinks Stationary or lowered Auto Mode Either pressed Raised Blinks Stationary or released Auto Mode Released Lowered Glows Rotates G-16 35 Series 4WD, Model - 3535, 4035, 4535 and 5035 SM June’08...
  • Page 285 3. Reflector & Rear Position Lamp LH 4. Rear Brake Lamp LH 5. Turn Signal Lamp RH 6. Reflector & Rear Position Lamp RH 7. Rear Brake Lamp RH G-17 35 Series 4WD, Model - 3535, 4035, 4535 and 5035 SM June’08...
  • Page 286 While refitting the fuse box cover care should be taken that clicking sound after fitting is heard. This ensures proper fitting of fuse box cover. G-18 35 Series 4WD, Model - 3535, 4035, 4535 and 5035 SM June’08...
  • Page 287 CHECK battery case retaining bolts and mountings regularly — poor mounting can cause extensive damage. NEVER overcharge for any length of time. Sealed battery cannot test for specific gravity. G-19 35 Series 4WD, Model - 3535, 4035, 4535 and 5035 SM June’08...
  • Page 288 The clutch consists of 5 rollers which run on cam track cut in inner member which is driven by the armature. The pinion is an integral part of the outer member. G-20 35 Series 4WD, Model - 3535, 4035, 4535 and 5035 SM June’08...
  • Page 289 29 "C" Washer 45 Pole Screw 14 Engaging Lever Assembly 30 Earth Terminal 46 Rear Bracket Assy. 15 Jump Ring (Pinion) 31 Spring (End Cover) 47 Screw (B.G. Fixing) G-21 35 Series 4WD, Model - 3535, 4035, 4535 and 5035 SM June’08...
  • Page 290 • Ensure that the starter motor mounting bolts are securely fastened. • Check and ensure that all electrical connections are firmly tightened. • Examine cables for fractures / cracks particularly at the terminal lugs. G-22 35 Series 4WD, Model - 3535, 4035, 4535 and 5035 SM June’08...
  • Page 291 2. Starter switch defective. 2. Repair or replace starter switch. but the engine 3. Check the battery condition. 3. Replace with charged battery. is not cranked Table No. 1 G-23 35 Series 4WD, Model - 3535, 4035, 4535 and 5035 SM June’08...
  • Page 292 Observe correct polarity of battery. Connect oil inlet, outlet and vacuum connection. Close the switch, warning lamp should glow. The oil pump and the main drive should be switched ‘ON’ simultaneously. G-24 35 Series 4WD, Model - 3535, 4035, 4535 and 5035 SM June’08...
  • Page 293 Disconnect all Alternator terminals, while Do not disconnect battery cables while the engine carrying out welding jobs on the vehicle. is running. Disconnect the battery earth cable before removing the Alternator. G-25 35 Series 4WD, Model - 3535, 4035, 4535 and 5035 SM June’08...
  • Page 294 PARKING LAMP, TAIL LAMP AND OTHER ELECTRICAL LOADS EXCEPT HEATER. IS RATED CURRENT OUTPUT REACHED WITHOUT VOLTAGE REMOVE THE ALTERNATOR AND CHECK DROPPING BELOW 13.5 VOLTS ? ALTERNATOR FOUND ACCEPTABLE G-26 35 Series 4WD, Model - 3535, 4035, 4535 and 5035 SM June’08...
  • Page 295 15. Stator Winding Assembly 49. Sealing Washer 32. Spring Washer 16. Rectifier Assembly 33. Nut 50. Screw 17. Aluminium Spacer 34. Sliding Bush 51. Oil Inlet Plug G-27 35 Series 4WD, Model - 3535, 4035, 4535 and 5035 SM June’08...
  • Page 296 Wiring Diagram - 35 Series G-28 35 Series 4WD, Model - 3535, 4035, 4535 and 5035 SM June’08...

  • Page 297: Steering

    G r o u p - H S t e e r i n g Steering ................. H1 – H19 35 Series 4WD, Model - 3535, 4035, 4535 and 5035 SM June’08...
  • Page 299 Rod ------------------------------------------------------------ ø 38 mm (1.50 in.) Stroke --------------------------------------------------------- 220 mm (8.66 in.) d) Filteration --------------------------------------------------------- Strainer 100 mesh and suction line filter 10 micron common with hitch circuit Maximum Operating Temperature ------------------------ 90 35 Series 4WD, Model - 3535, 4035, 4535 and 5035 SM June’08...
  • Page 300 Adaptor ( P & R Port On HSU ) Hose Pressure, HSU Integral Column Steering Control Unit Hose O'Ring for P, L, R & T Ports of HSU 35 Series 4WD, Model - 3535, 4035, 4535 and 5035 SM June’08...
  • Page 301 Assemble HSU unit Fit the HSU hose pipe, connections and bracketaries. Connect the linkages of hand accelerator and forward/reverse. Assemble scuttle cover. Fit the steering wheel and cap. 35 Series 4WD, Model - 3535, 4035, 4535 and 5035 SM June’08...
  • Page 302 If the fluid become milky, water contamination may be a problem. Take fluid level reading when system is cold. Contact your dealer-representative if you have specific questions. 35 Series 4WD, Model - 3535, 4035, 4535 and 5035 SM June’08...
  • Page 303 Steering STEERING SYSTEM CIRCUIT 35 Series 4WD, Model - 3535, 4035, 4535 and 5035 SM June’08...
  • Page 304 35 Series 4WD, Model - 3535, 4035, 4535 and 5035 SM June’08...
  • Page 305 When the steering wheel is turned to move the valve spool off its centered position this fluid is instantly available. 35 Series 4WD, Model - 3535, 4035, 4535 and 5035 SM June’08...
  • Page 306 Fit the RH side panel and close the hood. Start engine and operate hydraulics. Check all connections for leaks. Check oil level, add if necessary with the recommended grade of oil. H-10 35 Series 4WD, Model - 3535, 4035, 4535 and 5035 SM June’08...
  • Page 307 Investigate and correct any external leak in the steering system, no matter how minor the leak. • Clean or replace the filter as per the routine service schedule. H-11 35 Series 4WD, Model - 3535, 4035, 4535 and 5035 SM June’08...
  • Page 308 Inspect the cylinder bore that is out of round must be replaced. Inspect the piston and piston rod for scratches and wear, then check the piston rod or straightness. H-12 35 Series 4WD, Model - 3535, 4035, 4535 and 5035 SM June’08...
  • Page 309 • Oil level in reservoir. the steering for approximately five minutes. • Suction pipe and return oil filter condition. • External oil leakage. H-13 35 Series 4WD, Model - 3535, 4035, 4535 and 5035 SM June’08...
  • Page 310 Should these investigations bring no result, proceed to inspect the tandem pump, manual steering control unit (manual pump) and/or steering cylinder, refer to general information in respective section and follows trouble shooting chart. H-14 35 Series 4WD, Model - 3535, 4035, 4535 and 5035 SM June’08...
  • Page 311 Remove wear or damaged seals or o’rings and install with new one. If these seals or O'Rings damaged, this will result into external leakages. H-15 35 Series 4WD, Model - 3535, 4035, 4535 and 5035 SM June’08...
  • Page 312 (i.e.25Nm / 18 lb.ft.) NOTE: Whenever dismantling of steering cylinder for inspection/checking always replace piston seal, head cover seals, rod seals, wiper ring and O’Ring (Seal Kit). H-16 35 Series 4WD, Model - 3535, 4035, 4535 and 5035 SM June’08...
  • Page 313 Worn steering control unit meter. Replace steering control unit. E. Temporary hard steering Thermal Shock * Check unit for proper operation or hang-up and cause of thermal shock. H-17 35 Series 4WD, Model - 3535, 4035, 4535 and 5035 SM June’08...
  • Page 314 Steering column shaft worn or Repair or replace steering wheel wheel. damaged. There should be very connection or column. little free play in the unit itself. H-18 35 Series 4WD, Model - 3535, 4035, 4535 and 5035 SM June’08...
  • Page 315 C temperature differential). When the steering wheel is turned quickly the result is temporary seizure and possible damage to internal parts of the steering control unit. The temporary seizure may be followed by total free wheeling. H-19 35 Series 4WD, Model - 3535, 4035, 4535 and 5035 SM June’08...

  • Page 317: Hydraulics

    Group-I H y d r a u l i c s Hydraulics ..............I1 – I37 Auxiliary Valve .............. I38 – I40 35 Series 4WD, Model - 3535, 4035, 4535 and 5035 SM June’08...
  • Page 319 • Automatic hydraulic limit stop of angular excursion of lifting arms. • Sector control with two levers: One lever for the position and one for the draft control. 35 Series 4WD, Model - 3535, 4035, 4535 and 5035 SM June’08...
  • Page 320 Hydraulics 35 Series 4WD, Model - 3535, 4035, 4535 and 5035 SM June’08...
  • Page 321 & control valve. The cylinder of the system is protected by shock load relief valve. The control valve is operated by two levers. 35 Series 4WD, Model - 3535, 4035, 4535 and 5035 SM June’08...
  • Page 322 (28) which discharges chamber (15) by means of the duct (29) of the regulator piston (2). Thus the oil coming from the pump feeds chamber (22) and 35 Series 4WD, Model - 3535, 4035, 4535 and 5035 SM June’08...
  • Page 323 (6) and the variable connected to the inlet port of oil coming from throat made by the control spool (1) with the the pump. 35 Series 4WD, Model - 3535, 4035, 4535 and 5035 SM June’08...
  • Page 324 (17) causing oil to flow chamber (23) of the cylinder and the discharge to the tank. valve (4). The cylinder is always protected by accidental over-pressure by the safety valve (5). 35 Series 4WD, Model - 3535, 4035, 4535 and 5035 SM June’08...
  • Page 325 The position of the arms, during lifting and lowering, correspond to a specific position of the will transmit an anticlockwise rotation, by means of friction shock absorber (8), to the transmission position control lever (1). 35 Series 4WD, Model - 3535, 4035, 4535 and 5035 SM June’08...
  • Page 326 (21) free to move into neutral position (N) and continuing the movement of lever (2), in the discharge position (S), causing the arms to lower. I-10 35 Series 4WD, Model - 3535, 4035, 4535 and 5035 SM June’08...
  • Page 327 (11), acting on the draft cam (12), control, and at the same time ensuring the will move the distributor shaft (21) into the maximum possible depth desirable. I-11 35 Series 4WD, Model - 3535, 4035, 4535 and 5035 SM June’08...
  • Page 328 The implement movement is proportional to the movement range fixed by means of lever 1. I-12 35 Series 4WD, Model - 3535, 4035, 4535 and 5035 SM June’08...
  • Page 329 This can be on neutral -positive -negative - position depending on the draft force, or to the changement of force on the top link bracket depending on the implement weight. I-13 35 Series 4WD, Model - 3535, 4035, 4535 and 5035 SM June’08...
  • Page 330 (1) from the shaft (5). With the draft control lever (2) at its lowest position against the backstop (E) raise the position control lever (1) against the backstop (F). I-14 35 Series 4WD, Model - 3535, 4035, 4535 and 5035 SM June’08...
  • Page 331 F), raising completely the draft control lever (2) there is a further movement upwards of the rockshaft arms. This movement should be contained within 10-15 mm. I-15 35 Series 4WD, Model - 3535, 4035, 4535 and 5035 SM June’08...
  • Page 332 With the motor running at minimum RPM slowly raise the draft control lever (2). The adjustment of the draft lever (2) is correct when it is moved I-16 35 Series 4WD, Model - 3535, 4035, 4535 and 5035 SM June’08...
  • Page 333 112 0/+0.5 mm is correct. NOTE: If the measurement (X) is changed it is obligatory to carry out again the adjustment of the position and draft control levers. I-17 35 Series 4WD, Model - 3535, 4035, 4535 and 5035 SM June’08...
  • Page 334 41-50 Nm (30-37 Lb-ft.) Control Support Quadrant Linkage Screw 19-29 Nm (14-21 Lb-ft.) Bracket Synchro Lubrication Mounting Bolt 8-10 Nm (6-7 Lb-ft.) Compensator Linkages Cap Screw 88-98 Nm (65-72 Lb-ft.) I-18 35 Series 4WD, Model - 3535, 4035, 4535 and 5035 SM June’08...
  • Page 335 19-29 Nm (14-21 Lb-ft.) Crank Locking Screw 19-29 Nm (14-21 Lb-ft.) Cylinder Mounting Set Screw 98-127 Nm (72-94 Lb-ft.) Cylinder Mounting Set Screw 68-88 Nm (50-65 Lb-ft.) I-19 35 Series 4WD, Model - 3535, 4035, 4535 and 5035 SM June’08...
  • Page 336 19-29 Nm (14-21 Lb-ft.) Top Link Bracket Mounting Screw 39-49 Nm (29-36 Lb-ft.) Top Link Bracket Mounting Screw 39-49 Nm (29-36 Lb-ft.) Control Valve Mounting Screw 19-29 Nm (14-21 Lb-ft.) I-20 35 Series 4WD, Model - 3535, 4035, 4535 and 5035 SM June’08...
  • Page 337 Relief and Safety valves out Control calibration of the of calibration. valves. Poor pump efficiency. replace the pump Excessive loss of oil from Overhaul the Control Valve Control Valve. I-21 35 Series 4WD, Model - 3535, 4035, 4535 and 5035 SM June’08...
  • Page 338 Overhaul the rockshaft Rockshaft does not lift Preselector is fully closed Unscrew fully the preselector and the relief valve acts “P” with the possibility to damage the pump I-22 35 Series 4WD, Model - 3535, 4035, 4535 and 5035 SM June’08...
  • Page 339 Remove wiring connections and dismantle wiring from front platform. Remove gear lever rubber boot and knob. Lift the fender rear platform, sheet assembly. Removing of Control Levers Knob I-23 35 Series 4WD, Model - 3535, 4035, 4535 and 5035 SM June’08...
  • Page 340 Connect lift unit supply line. Tighten to torque to 60 Nm (45 lbs.ft). Install top link and connect lift links. Follow the reverse sequence of dismantling for assembly. I-24 35 Series 4WD, Model - 3535, 4035, 4535 and 5035 SM June’08...
  • Page 341 Remove socket head screw (A), two cap screw (B), lever position control (C) and hub (D). Loosen set screw (E) in link (F). I-25 35 Series 4WD, Model - 3535, 4035, 4535 and 5035 SM June’08...
  • Page 342 Install lever position control using socket head screw. Install linkages levers to control levers and secure with lock clips. Install lift unit. Adjust hydraulic control lever friction. I-26 35 Series 4WD, Model - 3535, 4035, 4535 and 5035 SM June’08...
  • Page 343 (E) and take it out. Remove snap ring (F) & (G). Loosen pin (H) & (I) and take out cam, compensator assembly and linkages. I-27 35 Series 4WD, Model - 3535, 4035, 4535 and 5035 SM June’08...
  • Page 344 Reverse the dismantling procedure for assembly and installation. NOTE: Apply thread sealant to allen set screws during assembly. Adjust hydraulic lift unit position and draft sensing feedback linkages. I-28 35 Series 4WD, Model - 3535, 4035, 4535 and 5035 SM June’08...
  • Page 345 Use O’Ring set (Seal kit - contains outer O’Rings of flow control valve) of flow control valve replacement. Use protective sleeve to install O’Rings on flow control valve. I-29 35 Series 4WD, Model - 3535, 4035, 4535 and 5035 SM June’08...
  • Page 346 Index parts to hydraulic with a punch mark before disassembly, to aid in correct alignment of these parts during assembly. Slightly tap lift arms to take out. I-30 35 Series 4WD, Model - 3535, 4035, 4535 and 5035 SM June’08...
  • Page 347 Install new seals around shaft. Install washers and arms on shaft, aligning indexing marks from disassembly. Install snap rings. Install hydraulic lift unit. I-31 35 Series 4WD, Model - 3535, 4035, 4535 and 5035 SM June’08...
  • Page 348 Inspect all part for wear or damage. Check piston and cylinder for cracks or scoring. Replace as necessary. Always use new seals. Old or damaged seals will leak. I-32 35 Series 4WD, Model - 3535, 4035, 4535 and 5035 SM June’08...
  • Page 349 Install piston with concave end facing opening of cylinder. Apply thread sealant to threads of allen set screws. Install hydraulic lift unit. I-33 35 Series 4WD, Model - 3535, 4035, 4535 and 5035 SM June’08...
  • Page 350 (E) and one set screw (F). Remove lock roll pin (G) of pin (H) , to take out top link bracket. I-34 35 Series 4WD, Model - 3535, 4035, 4535 and 5035 SM June’08...
  • Page 351 Install top link bracket assembly to hydraulic lift unit. Apply grease on spring before fitment. After complete assembly, grease through grease nipple provided on control support sleeve and top link bracket. I-35 35 Series 4WD, Model - 3535, 4035, 4535 and 5035 SM June’08...
  • Page 352 Assemble the connections to relief valve. Service Recommendation: It is not recommended to repair Relief Valve assembly. Relief Valve assembly should be completely replaced, if internal problem suspected. I-36 35 Series 4WD, Model - 3535, 4035, 4535 and 5035 SM June’08...
  • Page 353 Remove PTO control valve. Service Recommendation: It is not recommended to repair PTO Control Valve. PTO Control Valve should be completely replaced, if internal problem is suspected. I-37 35 Series 4WD, Model - 3535, 4035, 4535 and 5035 SM June’08...
  • Page 354 Loosen nuts (I) on cable outer and remove cable assembly from bracket auxiliary valve lever mounting (J) and remove cable out of fender assembly. Free the cable assembly (K) from fender guide clip. I-38 35 Series 4WD, Model - 3535, 4035, 4535 and 5035 SM June’08...

  • Page 355: Auxiliary Valve

    NOTE: Do not fit repaired auxiliary valve on the tractor. It is recommended to replace the complete auxiliary valve with cable assembly as a single unit. I-39 35 Series 4WD, Model - 3535, 4035, 4535 and 5035 SM June’08...
  • Page 356 O’Rings refer parts catalogue page of hydraulic lift housing Refitment of Single Spool Auxiliary Valve and Pipings For refitment of Auxiliary Valve and piping follow disassembly procedure in reverse sequence. I-40 35 Series 4WD, Model - 3535, 4035, 4535 and 5035 SM June’08...
  • Page 357 Front Axle - Side Section Speed Section - Transmission Speed Section - Transmission Range Section - Transmission Range Section - Transmission Lubrication & Greasing Chart - 35 Series 35 Series 4WD, Model - 3535, 4035, 4535 and 5035 SM June’08...
  • Page 360 Differential Assembly & Rear Axle 13. Taper Roller Bearing 14. Retainer Differential Carrier 15. Bush Bull Pinion Shaft Support 16. Bolt 17. Washer Thrust Bevel Gear Shaft Diffential Fork 18. Bevel Gear Differential LH O’ring 19. Carrier Differential LH Fork Differential 20.
  • Page 361 Rear Axle Carrier and Brake Assembly Flange Bolt Case, Oil Seal Retainer Rear Axle Carrier Collar Bull Gear Ball Bearing Bull Pinion Shaft Bearing Retainer Bolt M8 x 20 10. Brake Assembly 11. Bearing 12. Oil Seal 13. Rear Axle 14.
  • Page 362 Front Axle - Differential Beam Housing Grease Nipple Pillow Block Front Thrust Washer Differential Case Thrust Washer Bevel Pinion Differential Bevel Gear Differential Ring Gear 10. Shaft Beam Housing 11. Bearing Carrier 12. Housing Differential Carrier 13. Taper Roller Bearing 14.
  • Page 363 Front Axle - Side Section Shaft Beam Housing 15. Retainer Washer Spacer 16. Spindle Lock Nut 17. O’Ring Bearing 18. Hub Housing Bearing 19. Oil Seal Dip Stick 20. Ball Bearing Top Cover 21. Straight Bevel Gear Oil Seal 22. Bearing Swivel Housing 23.
  • Page 364 Speed Section - Transmission 12 13 16 17 22 23 1. Clutch Release Bearing 2. Clutch Housing 3. Sleeve Clutch Release 4. Shaft Clutch Release 5. Fork Clutch Release 6. Main Hollow Drive Shaft Shuttle 7. Retainer Main Drive Shaft 8.
  • Page 365 Speed Section - Transmission Neutral Speed 1 Speed 3 Forward Engaged Speed 2 Speed 4 Reverse Engaged...
  • Page 366 Range Section - Transmission 1. Bush High Driven Gear 2. Needle Roller Bearing 3. Gear Spline Shaft 4. Taper Roller Bearing 5. Needle Roller Bearing 6. Gear High Driven 7. Needle Roller Bearing 8. Gear 4WD Idler 9. Oil Seal 10.
  • Page 367 Range Section - Transmission...
  • Page 368 Lubrication & Greasing Chart - 35 Series D e s c r i p t i o n Lubricant Lift Rod RH Levelling Rod RH Pin Pivot Sensing Bracket Front Pillow Block Rear Pillow Block Speed Shift Mounting Bracket Engine Oil Level Check...

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