Mahindra ML 120 3535 Operator's Manual
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Mahindra ML 120 3535 Operator's Manual

35 series
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OPERATOR'S MANUAL
PARTS CATALOGUE
INSTALLATION INSTRUCTIONS
'35' Series
3535/4035
GEAR
ML 120
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  • Page 1 OPERATOR’S MANUAL PARTS CATALOGUE INSTALLATION INSTRUCTIONS '35' Series 3535/4035 GEAR ML 120 Click here to go on INDEX Main Menu contactus@almats.com...
  • Page 2 Includes: Operator’s Manual, Parts Catalogue and Installation Instructions Mahindra, Ltd Model ML120 Front End Loader 1503-1139 February 2008 35 Series 4WD, Model - 3535 & 4035 Loader June’08...
  • Page 3 WARRANTY CONDITIONS Warranty Coverage: Mahindra, Ltd, Inc., herein referred to as Mahindra, undertakes to replace or repair any part of a Mahindra loader where damage has been proven to be caused by defects in material or workmanship. This Warranty is valid for a period of 1 year for all hydraulic components and attachments and for a period of 2 years for all other loader components from the date of the original retail sale.
  • Page 4 CONGRATULATIONS You are now the proud owner of a MAHINDRA Loader. This loader is a product of quality engineering and manufacturing. It is made of fine materials and under a rigid quality control system. It will give you long, satisfactory service. To obtain the best use of your loader, please read this manual carefully.

  • Page 5: Safety Precautions

    23. Do not modify, alter, or permit anyone else to modify or alter the loader, any of its components, or any loader function without first consulting a Mahindra dealer. 24. Assemble, remove, and reinstall the loader only as directed in this manual. Failure to do this could result in serious personal injury or death.
  • Page 6 SAFETY PRECAUTIONS BEFORE OPERATION 26. Before starting the engine of your tractor, make sure all operating controls are in park lock or neutral position. 27. Be certain lights and safety markings, as provided by the tractor manufacturer, are clean and operating when transporting the tractor/loader on public roads.
  • Page 7 SAFETY PRECAUTIONS 50. If you must handle large heavy objects, protect yourself by using caution, moving slowly, and avoiding bumps and rough ground. 51. If you must handle large heavy objects, protect yourself by never lifting load higher than necessary to clear the ground.
  • Page 8 SAFETY PRECAUTIONS 79. High pressure oil leaks can penetrate skin causing serious injury and gangrene. Consult a physician immediately. 80. Lower the loader or boom and release hydraulic pressure before loosening fittings. AFTER OPERATION 81. Before leaving the tractor seat, lower attachment or loader boom to ground, stop engine, lock parking brakes, put all controls in neutral, relieve hydraulic pressure, and remove key before leaving operator's seat.
  • Page 9 DANGER, WARNING, AND CAUTION DECAL SAFETY MESSAGES 0595-3000 WARNING DECAL Add recommended rear wheel ballast and/or rear counter-weight for stability. Move wheels to widest recommended setting to increase stability. Move and turn tractor at low speeds. In transport carry the load low. Lower loader to the ground when parked.
  • Page 10 DANGER, WARNING, AND CAUTION DECAL SAFETY MESSAGES 0595-2190 CAUTION DECAL To prevent bodily injury and loader instability when detaching loader, equip loader with a material bucket. 0595-3050 DANGER DECAL To avoid serious injury or death: Unload only on a level surface. Keep bystanders clear of work area when loading and unloading bales.

  • Page 11: Safety Decals

    2. Clean safety decals with soap and water and dry with a soft cloth. 3. Replace damaged or missing safety decals with new decals from your Mahindra Dealer. 4. If a component with a safety decal(s) affixed is 0595-3004 replaced with a new part, make sure new safety decal(s) are attached in the same location(s) as the replaced components.
  • Page 12 7. Replace damaged or missing safety decals with new 0595-3001 decals from your Mahindra Dealer. 8. If a component with a safety decal(s) affixed is replaced with a new part, make sure new safety decal(s) are attached in the same location(s) as the replaced components.

  • Page 13: Table Of Contents

    TABLE OF CONTENTS 10.3. SKID STEER TOOL CARRIER SYSTEM SERVICE & LUBRICATION ....58 1. SPECIFICATIONS..........14 1.1. BUCKET SPECIFICATIONS.....14 11. INSTALLATION & OPERATION OF SKID STEER TOOL CARRIER SYSTEM ....59 2. INTRODUCTION ..........15 11.1. INSTALLATION INSTRUCTIONS ...59 11.2. SKID STEER TOOL CARRIER HANDLES 3.
  • Page 14 19.1. TROUBLE SHOOTING CABLES AND 27. LIFT CYLINDER ..........94 SINGLE LEVER CONTROLLER ....81 28. TILT CYLINDER ..........95 20. TORQUE CHART..........82 29. LOADER VALVE ..........96 21. PARTS MANUAL ..........83 30. SKID STEER TOOL CARRIER ATTACHMENT98 22. DECALS & MANUALS ........84 31. SKID STEER BUCKET ........100 23.

  • Page 15: Specifications

    1. SPECIFICATIONS Model ML120 Front End Loader For Use with Models 3 Cylinder 35 Series Tractors SPECIFICATIONS OF LOADER: ........................ML120 Maximum Lift Height to Pivot Pin....................8’ 9" (105") Maximum Lift Height under Level Bucket ................8’ 4.5" (100.5") Clearance with Bucket Fully Dumped ..................... 7’ 1" (85") Reach at Maximum Lift Height (to Grill Guard) .................

  • Page 16: Introduction

    If, at any time, you have a service problem with your loader or need new parts, contact your local Mahindra dealer. Your dealer will need the loader model number and serial number to give you prompt, efficient service. The serial number plate is located on the LH inside front area of boom.

  • Page 17: Installation Instructions

    3. INSTALLATION INSTRUCTIONS CAUTION: Equip your tractor with a ROPS cab or frame for your protection. See your tractor/ROPS Operator Manual for correct seat belt usage. Read entire instructions before beginning to install the loader. Personal injury and machine damage may be prevented if you read and understand these instructions and special safety messages.
  • Page 18 Rear tractor ballast is required after installation of loader on the tractor. Following is recommended ways to ballast your tractor. Install factory rear wheel weights to tractor. Install a Mahindra weight box to tractor 3-point. Install some type of 3-point attachment to tractor. Install a Mahindra backhoe to the tractor.

  • Page 19: Mounting Kit Installation

    3.2. MOUNTING KIT INSTALLATION 3.2.1. Position the tractor and loader on a hard level surface under a hoist. 3.2.2. Remove front weights from tractor if applicable. IMPORTANT: Do not tighten any hardware until all components are attached onto the tractor. CAUTION: Lift and support all loader components safely.
  • Page 20 3.2.4. Install RH engine spacer assembly using two 14-2.0 x 35 mm bolts and 9/16” disc-lock washers in two holes closest to the front of tractor. Install four 14-1.5 x 65 mm bolts and 9/16” disc-lock washers in remaining four holes. RH engine spacer assembly 14-1.5 x 65mm Gr.
  • Page 21 Photo shows overall view of installed right hand center bracket 3.2.6. Remove nuts and lockwashers from front two bolts on 3-point link plate located on the tractor right Front view rear axle housing. Install RH rear rail over two 3-point link plate bolts and secure with hardened flatwasher 5/8”...
  • Page 22 3.2.7. Install right hand side rear rail to RH center bracket using three ½”-13 x 2.0” Gr. 5 bolts and ½”-13 Front view stover hex locknuts ½”-13 x 2.0” Gr. 5 bolts, ½”-13 Stover Hex Locknuts, 3 places RH Rear Rail Rear view ½”-13 x 2.0”...
  • Page 23 A. Identify hardware size and grade. LH & RH center brackets spacer assembly B. Torque hardware to specification noted on torque hardware. chart, page 82, unless otherwise specified below. LH & RH center casting hardware. LH & RH side rail hardware. Refer to torque IMPORTANT NOTE: To keep mounting kit hardware chart, page 82.

  • Page 24: Loader Installation

    3.3. LOADER INSTALLATION CAUTION: Lift and support all loader components safely. IMPORTANT: Do not extend tilt cylinders without attachment pinned to loader. Failure to follow these instructions could cause loader damage and void warranty. 3.3.1. Loader valve hoses and quick couplers have been pre-assembled on loader. Unwrap these hoses by cutting nylon ties securing them to side of loader.

  • Page 25: Hydraulic Installation

    3.4. HYDRAULIC INSTALLATION 3.4.1. Install three ¾” ORBM x ¾” JICM straight fittings into the “In”, “Out” and “PB” ports of the loader valve. ¾” ORBM x ¾” JICM straight fitting in “In” Port of Loader Valve ¾” ORBM x ¾” JICM straight fitting in “Out”...
  • Page 26 3.4.4. Install two 9/16” JICM x 9/16” ORBM 90° fittings on two fittings installed in the “A” and “C” ports of the loader valve. Position these fittings as shown. 9/16” JICM x 9/16” ORBM 90° fittings in ports “A” and “C” 3.4.5.
  • Page 27 3.4.7. Install valve mount to RH center bracket using hex head cap screw 5/16” x 1.25”, 5/16” flatwasher and 5/16” stover hex locknut as shown. Valve mount should be installed as shown and angle slightly towards the center of the tractor. Hex Head Cap Screw 5/16”...
  • Page 28 Power Beyond Return Pressure 3.4.9. Remove plugs from tractor hydraulic block located under the right hand side of tractor floorboard. Install 22” hydraulic hose assembly ¾” JICF 90° x ¾” JICF to pressure port of tractor and connect to fitting in “In”...
  • Page 29 22” Hydraulic Hose Assembly ¾” JICF 90° x ¾” JICF connected to Power Beyond port of Tractor and connected to fitting in “PB” port of loader valve. Route hose as shown Valve Port Circuit Information: Port "A" to Tilt Cylinder Base End – Yellow Tie Port "B"...
  • Page 30 3.4.10. Remove cutout in floorboard rubber mat located directly in front of right hand fender. Install single handle controller mount to tractor platform directly in front of right hand fender using hex head cap screw 3/8”-16 x 1.25” and 3/8”-16 stover hex locknut, 4 places as shown.
  • Page 31 3.4.11. Route single handle controller cables through platform hole then install spacer plate, single handle controller with cables and cover plate using hex head cap screw 5/16”-18 x 3.5”, flatwasher 5/16” and stover hex locknut 5/16”-18 as shown. Install spacer in bottom hole of single handle controller mount as shown.
  • Page 32 3.4.13. To allow handle to function correctly connect single handle controller to loader valve as described in next step. 3.4.14. Install the following components to both cables in order they are numbered. 1.1. Thread jam nut the entire length of threads on cable so it rests on cable.
  • Page 33 3.4.15. Install cables to valve. 1.11 1.10 1.12 1.9. Turn cable adjuster onto Lift Spool closest threads until flush with to plug valve surface. Make sure handle remains in neutral position. 1.10. Tighten jam nut against cable adjuster to lock in position.
  • Page 34 3.4.17. Install toolbox to right hand centerbracket using hex head cap screw 5/8”-12 x 2.5” and stover hex locknut 5/8”-12 as shown. Toolbox Hex Head Cap Screw 5/8”-12 x 2.5”, Stover Hex Locknut 5/8”-12, 2 places 3.4.18. Install step removed in step 3.2.3 on right hand rear rail using original step hardware as shown.

  • Page 35: Pre-Operation Instructions

    4. PRE-OPERATION INSTRUCTIONS 4.1. HYDRAULIC FLUID Check the tractor hydraulic fluid level and fill, if required. 4.2. INITIAL LOADER OPERATION NOTE: If any loader cavitation is noticed during loader operation, check tractor hydraulic fluid level and correct. NOTE: Keep engine speed at low idle during the initial loader operation. CAUTION: Escaping hydraulic fluid under pressure can have sufficient force to Cardboard...

  • Page 36: Loader Mounted Valve Equipped

    4.5. LOADER MOUNTED VALVE EQUIPPED WITH SINGLE HANDLE CONTROLLER 4.5.1. Your loader utilizes a series type loader mounted valve equipped with single handle controller and it will function as described. Number 1 Position: Number 7 Position: Pull single handle controller back to raise loader. Push the single handle controller forward and push Number 2 Position: the single handle controller outward to lower loader...

  • Page 37: Regenerative Dumping Position

    4.8. REGENERATIVE DUMPING POSITION Your valve is equipped with a regen position in the bucket circuit. When digging with the loader, feather the single handle controller outward to angle the bucket forward and put the weight of the tractor on the cutting edge. If you position the loader valve into regen position, weight of the tractor may not remain on the cutting edge.

  • Page 38: Removing Air From Hydraulic System

    IMPORTANT: Always lock loader valve handle in locked position when loader is not in use or when loader has been parked from tractor. Push lock downward until red button is exposed for locked position Pull lock upward until green button is exposed for unlocked position NOTE: The Single Handle Controller is equipped with a handle lock that...

  • Page 39: Daily Maintenance & Lubrication

    5. DAILY MAINTENANCE & LUBRICATION 5.1. DAILY CHECKS 5.1.1. CRITICAL: Check all hardware daily before operation. Tighten hardware to torque values as specified in the Torque Chart, page 82 unless otherwise specified in this manual. IMPORTANT NOTE: To prevent mounting kit hardware from loosening during operation always torque mounting kit hardware to specified torque noted in loader operator manual.

  • Page 40: Loader Lubrication And Service

    5.1.3. Service your loader at the intervals and locations as specified. When you service your loader, use only high quality lubricants. The engine hour meter on the tractor shows the amount of hours the engine has worked. Use the hour meter to service your loader at the correct time periods. IMPORTANT: Lower the loader boom to the ground and relieve pressure in loader hydraulic lines prior to doing any service or maintenance operations on the tractor or loader.
  • Page 41 CAUTION: Do not stand, walk, or work under a raised loader or attachment unless it is securely blocked or held in position. Accidental movement of the valve handle/handles or leaks in the hydraulic system could cause the loader to drop, or attachment to dump, causing severe injury. Before servicing your tractor, always do one of the following.

  • Page 42: Operating Instructions

    6. OPERATING INSTRUCTIONS The loader should be operated with the tractor engine running at mid rpm. Excessive speeds are dangerous, and may cause bucket spillage and unnecessary strain on the tractor and loader. When operating in temperatures below 30 F, run the tractor engine below 1200 rpm until the hydraulic fluid temperature exceeds 30 The following text and illustrations offer suggested loader and tractor operating techniques.

  • Page 43: Dumping The Bucket

    6.4. DUMPING THE BUCKET Lift the bucket just high enough to clear the side of the vehicle. Move the tractor in as close to the side of the vehicle as possible, then dump the bucket. 6.5. LOWERING THE BUCKET After the bucket is dumped, back away from the vehicle while lowering and rolling back the bucket.

  • Page 44: Peeling And Scraping

    It is important to keep the bucket level when approaching a bank or pile. This will help avoid gouging the work area. 6.8. PEELING AND SCRAPING Use a slight bucket down angle, travel forward, and hold the lift control forward to start the cut. Make a short cut and breakout cleanly.

  • Page 45: Handling Large Heavy Objects

    Operate at right angles to the ditch, take as big a bite as the tractor can handle. Leave dirt that drifts over the side of the bucket for final clean up. Pile dirt on the high side for easier backfilling on a slope.

  • Page 46: Back Grading Or Dozing Material45

    6.12. BACK GRADING OR DOZING MATERIAL When back grading, the angle between the bottom of the bucket and the ground must not be more than 15 degrees. Failure to follow these instructions could cause loader tilt cylinders to fail and void warranty. Do not exceed15°...

  • Page 47: Prohibited Operations

    6.13. PROHIBITED OPERATIONS 6.13.1. Never perform following operation with a Step 1: Extend loader. Failure to follow these instructions could cause lift cylinders Step 2: Hook high pressure spikes in system causing failure or bucket edge to damage to cylinders, hoses or loader frame members. solid object Step 1: Extend lift cylinder Step 2: Hook bucket edge to solid object...

  • Page 48: Dismounting The Loader

    7. DISMOUNTING THE LOADER CAUTION: Always park loader with material bucket attached to the loader. Never park loader with Bale Spear or Pallet Fork attached to loader. CAUTION: Before leaving the tractor seat, lower attachment or loader boom to ground, stop engine, lock brakes, relieve hydraulic pressure, and remove key.
  • Page 49 7.1.4. Remove handle pins from bearing boxes. Bearing box Handle pin 7.1.5. Remove parking stand from storage position in the boom cross tube. Return hairpin cotter to storage position. Hairpin cotter in storage position Parking stand in storage position 35 Series 4WD, Model - 3535 & 4035 Loader June’08...
  • Page 50 7.1.6. Position parking stand in attaching bracket located in center of cross tube. Secure using clevis pin and hairpin cotter. Attaching bracket Clevis pin and hairpin cotter in park position Parking Stand in park position 7.1.7. Photo shows parking stand in park position and handle pins removed from bearing boxes.
  • Page 51 7.1.9. Retract lift cylinders (C) until bearing box pins (D) rotates out of tower hooks and loader bracket towers. 7.1.10. Slowly drive tractor forward (E) while retracting tilt cylinders (F). Doing this will allow bearing boxes to guide loader as it is being parked off of tractor. Bearing boxes 7.1.11.
  • Page 52 7.1.14. Reinstall handle pins and snap pins to bearing boxes for storage. 7.1.15. Disconnect loader hoses from quick couplers. Start tractor and slowly back tractor away from the loader IMPORTANT: To avoid hydraulic hose damage, be alert and make sure hoses do not catch on tractor and/or loader during mounting or dismounting.

  • Page 53: Mounting The Loader

    8. MOUNTING THE LOADER CAUTION: Do not stand, walk, or work under a raised loader or attachment unless it is securely blocked or held in position. Accidental movement of valve handle/handles or leaks in the hydraulic system could cause the loader to drop, or attachment to dump, causing severe injury. CAUTION: Do not allow bystanders in loader work area.
  • Page 54 8.1.5. Position lift cylinders so they are fully retracted. Then drive tractor forward. Use tilt cylinders to position height of bearing box top pin making sure all loader components clear all tractor components. 8.1.6. Align bearing box top pin with tower top receiver guide post, both sides.
  • Page 55 8.1.9. Secure loader to center brackets by reinstalling handle pins to bearing boxes and secure handle pins using snap pins. Bearing box Handle pin Snap pin 8.1.9. Remove parking stand from parked position. Return clevis pin and hairpin cotter to attaching bracket for storage.
  • Page 56 8.1.10. Return parking stand to storage position in the boom cross tube. Secure using hairpin cotter. Hairpin cotter in storage position Parking stand in storage position IMPORTANT: To avoid hydraulic hose damage, be alert and make sure hoses do not catch on tractor and/or loader during mounting or dismounting.

  • Page 57: Optional Grill Guard

    9. OPTIONAL GRILL GUARD 9.1. INSTALLATION INSTRUCTIONS 9.1.1. Install attachment assembly to tractor using hardware indicated. Install locking spring pull pins into attachment assemby as shown. Attachment Assembly Locking Spring Pull Pins Hex Head Cap Screw 5/8”-12 x 2.0” Gr. 8, Hardened Flatwasher 5/8”, Stover Hex Locknut 5/8”-12, 4 places each...

  • Page 58: Skid Steer Tool Carrier System

    10. SKID STEER TOOL CARRIER SYSTEM NOTE: Some photos in this section are generic photos. IMPORTANT: Read safety information in this section and on decal before operating attachment. NOTE: Skid Steer Tool Carrier System is optional equipment WARNING: Always read and follow operating instructions before operating Skid Steer Tool Carrier System.

  • Page 59: Skid Steer Tool Carrier System Service & Lubrication

    10.3. SKID STEER TOOL CARRIER SYSTEM SERVICE & LUBRICATION IMPORTANT: To maintain your Skid Steer Tool Carrier System functioning properly, always keep handle components and latching areas clean. Keep these areas clean Keep these areas clean on your attachment 10.3.1. Inspect latching components and pins. If damaged, only replace with Factory approved components.

  • Page 60: Installation & Operation Of Skid Steer Tool Carrier System

    11. INSTALLATION & OPERATION OF SKID STEER TOOL CARRIER SYSTEM IMPORTANT: Read safety information in this section and on decal before operating attachment. WARNING: Always read and follow operating instructions before operating Skid Steer Tool Carrier System. 11.1. INSTALLATION INSTRUCTIONS IMPORTANT: Do not extend bucket cylinders without Skid Steer Tool Carrier installed on loader.

  • Page 61: Skid Steer Tool Carrier Handles In Disengaged Position

    11.2. SKID STEER TOOL CARRIER HANDLES IN DISENGAGED POSITION 11.2.1. To position handles into the handle disengaged position, rotate skid steer tool carrier handle upward. Rotate handles upward 11.3. SKID STEER TOOL CARRIER HANDLES IN ENGAGED POSITION 11.3.1. To position handles into the handle engaged position, rotate skid steer tool carrier handle...

  • Page 62: Installing Bucket Or Attachment To Skid Steer Tool Carrier

    12. INSTALLING BUCKET OR ATTACHMENT TO SKID STEER TOOL CARRIER IMPORTANT: Refer to Page 60 for instructions concerning Skid Steer Tool Carrier Handles Disengaged and Engaged Positions. CAUTION: Before leaving the tractor seat, stop the engine and lock brakes when installing or removing bucket or attachment.
  • Page 63 12.1.4. When Skid Steer Tool Carrier attachment is aligned with bucket or attachment, raise loader boom slowly making sure Skid Steer Tool Carrier vee components engage. Then roll Skid Steer bucket or attachment back slowly. 12.1.5. Position loader so attachment is approximately 1"...
  • Page 64 12.1.8. Inspect Skid Steer Tool Carrier attaching areas to verify that Skid Steer Tool Carrier pins have engaged bucket or attachment fully. Bucket or attachment support bar Skid steer tool carrier pin assembly engaging bucket or attachment IMPORTANT: If properly latched into skid steer tool carrier attachment, the lower groove pin should be contacting pin support bar.

  • Page 65: Removing Bucket Or Attachment From Skid Steer Tool Carrier

    13. REMOVING BUCKET OR ATTACHMENT FROM SKID STEER TOOL CARRIER IMPORTANT: Refer to Pages 60 for instructions concerning Skid Steer Tool Carrier Handles Disengaged and Engaged Positions. CAUTION: Before leaving the tractor seat, stop the engine and lock brakes when installing or removing bucket or attachment.

  • Page 66: Skid Steer Bucket

    NOTE: Factory skid steer bucket comes in 72” width only. Never use a bucket wider than 72” and with a higher struck capacity than 12.5 cu. ft. on ML120 Mahindra loader. Failure to follow these instructions will cause tractor over-load and void warranty.

  • Page 67: Skid Steer Bale Spear

    15. SKID STEER BALE SPEAR CAUTION: To improve tractor and loader stability and to prevent overloading tractor front axle never handle any material with the following attachments that exceed weight specifications noted. IMPORTANT: Read safety information in this section and on decals before operating attachments.

  • Page 68: Skid Steer Bale Probe

    15.1. SKID STEER BALE PROBE IMPORTANT: This spear is a high strength alloy – drop forged steel and should not be welded or heat treated. IMPORTANT: Maximum load limit on super penetrator bale spear is 2,000 pounds. Do not handle round bales that weigh over 1,200 pounds with this unit.

  • Page 69: Skid Steer Pallet Fork

    16. SKID STEER PALLET FORK CAUTION: To improve tractor and loader stability and to prevent overloading tractor front axle never handle any material with the following attachments that exceed weight specifications noted. IMPORTANT: Read safety information in this section and on decals before operating attachments. To avoid serious injury or death: Do not use pallet fork attachment to lift ROPS (Roll-Over Protective Structures) and...

  • Page 70: Skid Steer Pallet Fork

    16.1. SKID STEER PALLET FORK 16.1.1. The Skid Steer Pallet Fork has two tines each 1-1/4" x 4" x 42". 16.2. ASSEMBLY INSTRUCTIONS 16.2.1. Install (3) pallet fork tines to (4) pallet fork frame using (1) pins, 2 places secure using (2) 3/8" x 2-1/2"...

  • Page 71: Optional Ballast Box

    17. OPTIONAL BALLAST BOX Category 1 ballast boxes listed below are available from your authorized Mahindra dealer. Category 1 3-point hitch 7.0 cubic feet capacity. Category 1 3-point hitch 5.0 cubic feet capacity. Refer to section 3.1.4. Recommended Rear Tractor Ballast in front of this manual for correct ballast for your tractor/loader combination.

  • Page 72: Leak Down Inspection

    18. LEAK DOWN INSPECTION IMPORTANT NOTE: Following leakage test should only be done by a qualified mechanic. 18.1. FRONT END LOADER FIELD LEAK DOWN INSPECTION AND TEST CAUTION: Do not stand, walk, or work under a raised loader tilt or attachment unless it is securely blocked and held in position.

  • Page 73: Leakage Test For Lift Cylinder Seals (Open Center Systems)

    IMPORTANT: Always check leakage of lift cylinder seals before you test lift circuit loader valve spool leakage. 18.2. LEAKAGE TEST FOR LIFT CYLINDER SEALS (Open Center Systems) NOTE: Clean all parts thoroughly before disassembling any fittings. Cycle or operate the hydraulic system till the control valve is warm to the touch.
  • Page 74 High Pressure Ball Valve and fittings installed on a loader. Lift Cylinder Rod End Hose Tee Fitting High Pressure Ball Valve Drain Hose 18.2.4. Install a pressure gauge in the lift circuit base end. 18.2.5. With high pressure ball valve in off position, place a load in the bucket and raise loader to some height. The load in the bucket and the lift height should be such that it induces a target reference pressure of 1500 psi in the cylinders.

  • Page 75: Leakage Test For Lift Circuit Loader Valve Spool

    IMPORTANT: Always check leakage of lift cylinder seals before you test lift circuit loader valve spool leakage. 18.3. LEAKAGE TEST FOR LIFT CIRCUIT LOADER VALVE SPOOL NOTE: Clean all parts thoroughly before disassembling any fittings. Cycle or operate the hydraulic system till the control valve is warm to the touch.

  • Page 76: Tilt Or Bucket Cylinder Valve Spool Leakage

    18.4.4. Place a load in the bucket and raise the boom slightly off the ground. The load should be such that it induces a target reference pressure between 1000 to 1500 psi in the cylinders refer to pressure gauge previously installed. 18.4.5.

  • Page 77: Acceptable Lift Cylinder Leak Down Rates

    18.6. ACCEPTABLE LIFT CYLINDER LEAK DOWN RATES IMPORTANT: Always double check your cylinder size to make sure it matches the information below. lift cylinder 18.6.1. Following are the allowable leak down rates specific to your loader sizes. If your loader is equipped with a load sense system acceptable leakage rates can be 30% higher than shown in this chart.

  • Page 78: Trouble Shooting Procedures

    19. TROUBLE SHOOTING PROCEDURES This Trouble Shooting Chart is provided for reference to possible loader operational problems. Determine the problem that best describes the operational problem being experienced and eliminate the possible causes as listed by following the correction procedures. For further assistance contact your dealer.
  • Page 79 PROBLEM POSSIBLE CAUSE CORRECTION Quick disconnect coupler restriction Check coupler connections. Repair or coupler. or replace. Hydraulic hose or tubeline Check hoses and tubelines for restriction (hoses/tubeline kinked or evidence of restriction. pinched). Lift cylinder piston assembly Check cylinders for leakage. Repair leakage.
  • Page 80 PROBLEM POSSIBLE CAUSE CORRECTION Loader drops with loader valve Cylinder Piston assembly leakage. Check cylinders for leakage. spool in "Centered" position (no external oil leakage evident.) Loader valve internal leakage. Replace loader valve and recheck. Note: A gradual drop over an extended period of time is a normal condition.
  • Page 81 Cycle lift cylinders and tilt cylinders. raising or lowering. Oil level too low. Add oil as required. Slow leakdown. Worn loader valve. Have authorized Mahindra dealer replace seals. Worn cylinder piston seals. Have authorized Mahindra dealer replace seals. Attachment will dump but will not Hydraulic circuit connected Check that Port "C"...

  • Page 82: Trouble Shooting Cables And Single Lever Controller

    19.1. TROUBLE SHOOTING CABLES AND SINGLE LEVER CONTROLLER PROBLEM POSSIBLE CAUSE CORRECTION Single handle controller will not Cable not adjusted properly. With single lever controller handle operate all valve functions. lock disengaged, readjust cable for correct valve operation. Check for damage to single lever Replace damaged part and readjust controller or cable.

  • Page 83: Torque Chart

    20. TORQUE CHART 35 Series 4WD, Model - 3535 & 4035 Loader June’08...

  • Page 84: Parts Manual

    21. PARTS MANUAL Illustrations All parts are illustrated in "exploded views" which show the individual parts in their normal relationship to each other. Reference numbers are used in the illustrations. These numbers correspond to those in the "Reference Number" column and are followed by the quantity required and description. Directional Reference Right hand (RH) and left hand (LH) sides are determined by standing at the rear of the unit and facing in the direction of forward travel.

  • Page 85: Decals & Manuals

    22. DECALS & MANUALS Mahindra Do not operate without confirmation that coupler pins are fully engaged. Loader attachment can fall off if not properly attached. To avoid serious injury or death: Only use loader manufacturer approved attachments. Read all operators manuals and decals before operating. Follow all sefaty, operating, and service instructions.
  • Page 86 2 ......Decal – Warning...............0595-3001 ........1 3 ......Decal – Danger ................0595-3002 ........1 4 ......Decal – Warning...............0595-3003 ........1 5 ......Decal – Warning...............0595-3004 ........1 6 ......Decal – Mahindra ..............0595-3101 ........2 7 ......Decal – Caution................0595-2190 ........1 8 ......Decal – Warning...............0595-3051 ........1 9 ......Manual, Operator and Parts.............1503-1139 ........1 10 ......Decal, ML120 ................0595-3127 ........2...

  • Page 87: Boom Assembly

    23. BOOM ASSEMBLY 35 Series 4WD, Model - 3535 & 4035 Loader June’08...
  • Page 88 BOOM ASSEMBLY Reference Description Part No. Qty. 1 ......Boom Assembly ...............1100-3043 ........1 2 ......Parking Leg Assembly .............1104-3059 ........1 3 ......Bearing Box, LH ...............1002-3132 ........2 4 ......Plated Pin Assembly ..............0551-3029 ........2 5 ......Lynch Pin..................0553-4503 ........2 6 ......Grease Fitting Straight 1/4"-28..........0530-1038 ........4 7 ......Pivot Pin 1”...

  • Page 89: Mounting Brackets And Hardware

    24. MOUNTING BRACKETS AND HARDWARE Tractor Hardware Tractor Hardware 35 Series 4WD, Model - 3535 & 4035 Loader June’08...
  • Page 90 MOUNTING BRACKETS AND HARDWARE Reference Description Part No. Qty. 1 ......Center Bracket LH..............1245-3516 ........1 2 ......Center Bracket RH ..............1245-3517 ........1 3 ......Rear Rail LH................1207-3110 ........1 4 ......Rear Rail RH ................1207-3111.........1 5 ......Cross Member................1209-3066 ........1 6 ......Spacer Assembly LH ..............1245-3602 ........1 7 ......Spacer Assembly RH ...............1245-3603 ........1 8 ......Hex Head Cap Screw ¾”-10 x 2.0”...

  • Page 91: Hydraulic Cylinders And Hoses

    25. HYDRAULIC CYLINDERS AND HOSES 35 Series 4WD, Model - 3535 & 4035 Loader June’08...
  • Page 92 HYDRAULIC CYLINDERS AND HOSES Reference Description Part No. Qty. 1 ......Cylinder, Tilt................3150-2106 ........2 2 ......Cylinder, Lift ................3160-2076 ........2 3 ......Hose Cover ................1212-2020 ........1 4 ......Top Hose Cover ...............1212-2019 ........1 5 ......Side Hose Cover ..............1212-2021 ........1 6 ......Sponge Rubber 3"..............0554-2010 ........6 7 ......Hydraulic Hose Assembly 3/8”...

  • Page 93: Hydraulic Valve And Hardware

    26. HYDRAULIC VALVE AND HARDWARE 35 Series 4WD, Model - 3535 & 4035 Loader June’08...
  • Page 94 HYDRAULIC VALVE AND HARDWARE Reference Description Part No. Qty. 1 ......Hydraulic Hose Assembly 3/8" x 22" ........¾” JICF x ¾” JICF 90° "In" and “Out” ........0582-2508808022 ....2 2 ......Hydraulic Hose Assembly 3/8” x 32" ........¾” JICF x ¾” JICF 90° "PB” .............0582-1508808032 ....1 3 ......Hydraulic Adapter 90˚...

  • Page 95: Lift Cylinder

    27. LIFT CYLINDER 2.0” x 1.25” Rod x 31.25” Ret. x 50.38” Ext. Reference Description Part No. Qty. 0 ......Lift Cylinder (complete) ............3160-2076 ........1 1 ......Tube Assembly.................0100-2126 ........1 2 ......Nut....................0530-2020 ........1 3 ......Piston ..................0405-2041 ........1 4 ......Seal Kit..................0590-2082 ........1 5 ......Head..................0330-2046 ........1 6 ......Rod Assembly ................0200-2116 ........1 ........Grease Fitting Straight .............0530-1038 ........2 7 ......Hydraulic Adapter..............0586-1108-408 ......2...

  • Page 96: Tilt Cylinder

    28. TILT CYLINDER 2.0” x 1.25” Rod x 27.38” Ret. x 48.07” Ext. Reference Description Part No. Qty. 0 ......Tilt Cylinder (complete) ............3150-2106 ........1 1 ......Tube Assembly.................0100-2127 ........1 2 ......Nut....................0530-2020 ........1 3 ......Piston ..................0405-2041 ........1 4 ......Seal Kit..................0590-2082 ........1 5 ......Head..................0330-2045 ........1 6 ......Rod Assembly ................0200-2117 ........1 ........Grease Fitting Straight .............0530-1038 ........2 7 ......Hydraulic Adapter..............0586-1108-408 ......2...

  • Page 97: Loader Valve

    29. LOADER VALVE Reference Description Part No. Qty. Seal Kit Complete (contains all of the following :) ..........0580-6347 ........1 1 ......O-Ring (Spool/Casting Seal)............SK..........4 2 ......O-Ring (Load Check Seal)............SK..........1 Spool End Float Kit Complete (contains all of the following :)......0580-6351 ........1 6 ......Spacer ..................NSS ..........1 7 ......Stop Cup ..................NSS ..........1 8 ......Spring ..................NSS ..........1...
  • Page 98 Spool End Regen Kit Complete (contains all of the following :) .......0580-6352 ........1 6 ......Spacer ..................NSS ..........1 7 ......Stop Cup ..................NSS ..........1 8 ......Spring ..................NSS ..........1 9 ......Washer ..................NSS ..........1 10 ......Detent Retainer ................NSS ..........1 11 ......Steel Ball ..................NSS ..........2 12 ......Spring ..................NSS ..........1 13 ......Poppet..................NSS ..........1 14 ......Cap Screw................NSS ..........2...
  • Page 99 30. SKID STEER TOOL CARRIER ATTACHMENT IMPORTANT Loader attachment cylinders must be pinned to correct hole or cylinder damage will occur voiding warranty. Pin ML130 this hole Only Pin ML120 this hole Only 0595-3144 Do not operate without confirmation that coupler pins are fully engaged. Loader attachment can fall off if not properly attached.

  • Page 100: Skid Steer Tool Carrier Attachment98

    SKID STEER TOOL CARRIER ATTACHMENT Reference Description Part No. Qty. 0 ......Skid Steer Tool Carrier Attachment (complete) ......1304-3164 ........1 1 ......Skid Steer Tool Carrier Frame..........1304-3165 ........1 2 ......Handle, LH ................1304-3060 ........1 3 ......Handle, RH................1304-3061 ........1 4 ......Hex Head Cap Screw 5/16"-18NC x 5-1/2" ......0545-2044 ........2 5 ......Flat Washer 5/16"..............0540-2001 ........2 6 ......Hex Lock Nut –...

  • Page 101: Skid Steer Bucket

    31. SKID STEER BUCKET Reference Description Part No. Qty. 1 ......Skid Steer Bucket 72" ..............1300-3605 ........1 35 Series 4WD, Model - 3535 & 4035 Loader June’08...

  • Page 102: Skid Steer Pallet Fork

    32. SKID STEER PALLET FORK To avoid serious injury or death: Do not use pallet fork attachment to lift ROPS (Roll-Over Protective Structures) and large objects, round bales, or items that seat belt equipped tractors are recommended may roll or slide down loader arms onto for operator use in all pallet fork operations.

  • Page 103: Skid Steer Bale Spear

    33. SKID STEER BALE SPEAR Reference Description Part No. Qty. 0 ......Skid Steer Bale Spear ..............1305-2023 ........1 1 ......Bale Spear Frame ..............1305-2024 ........1 2 ......Tine Assembly w/ nut, 1250 mm ..........1305-2013 ........1 3 ......Tine Assembly w/ nut, 900 mm ..........1305-2012 ........1 4 ......Decal Caution................0595-2190 ........1 5 ......Decal Danger ................0595-3050 ........1 6 ......Decal Danger ................0595-3054 ........1...

  • Page 104: Optional Grill Guard

    34. OPTIONAL GRILL GUARD Reference Description Part No. Qty. 1 ......Grill Guard Assembly ...............1008-3201 ........1 2 ......Headlight Protector Assembly..........1008-3221 ........1 3 ......Hex Head Cap Screw 5/8”-12 x 2.0” Gr. 8 .......0548-2166 ........4 4 ......Hardened Flatwasher 5/8” ............0540-2004 ........4 5 ......Stover Hex Locknut 5/8”-12 .............0546-1134 ........4 6 ......Hex Head Cap Screw ½”-13 x 2.0”...

This manual is also suitable for:

Ml 120 4035Ml 12035354035

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