Yanmar EF-494T Service Manual

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EF494T TM 06/2011 edition

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EF494T TM 06/2011 edition

SAFETY

Never attempt to operate or service this machine until you have first read and understood all of the applicable Safety Instructions that are set forth in this Manual.

The failure to comply with all relevant Safety Instructions could result in bodily injury.

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TABLE OF CONTENTS TABLE OF CONTENTS

EF494T TM 06/2011 edition

TABLE OF CONTENTS

0 INTRODUCTION

To The Owner MAINTENANCE SUPPLY PERIOD FOR MAINTENANCE PARTS IMPROVEMENTS SYMBOL INDICATION

1 1 1 1 2

0.1 PRECAUTIONS FOR THE SAFE SERVICES

0.2 AFTER SALES SERVICE

0.3 GENERAL PRECAUTIONS FOR SERVICES

0.3.1 GENERAL

0.3.2 USAGE OF THE LIQUID GASKET

0.3.3 SCREW TIGHTENING TORQUE TABLE

0.3.4 FUSE BOX

0.3.5 PART NAMES

0.3.6 SAFETY LABEL LOCATION

0.3.7 SPECIFICATIONS

0.3.8 TRACTOR MASS AND TIRE SPECIFICATION

12 14 16 17 18 20 21 21

1 PERIODICAL INSPECTION

1.1 CHECK INTERVALS

1.2 OIL AND GREASE

1.3 OIL AND WATER VOLUME

1.4 EQUIVALENT TO TF-500

1.5 REPLACING OIL

1.6 REPLACING FILTER ELEMENTS

1.7 REPLACING COOLING WATER

1.8 REMOVING WATER FROM WATER SEPARATOR

1.9 CLEANING AND REPLACING AIR CLEANER ELEMENT, CLEANING RADIATOR SCREEN

1.10 CHECKING BATTERY

1.11 CHECKING HOSE AND PIPE

1.12 CHECKING ELECTRICAL WIRING

1.13 GREASING

1.14 ADJUSTING BRAKE

1.15 ADJUSTING CLUTCH

1.16 ADJUSTING STEERING WHEEL

1.17 ADJUSTING FAN BELT

1.18 ADJUSTING TOW-IN

1.19 REPLACING FUSE

1.20 CHECKING TIRES

1.21 COLOR OF EXHAUST GAS

23 24 24 24 25 27 28 29 30

31 31 32 33 36 37 37 38 38 39 40 40

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TABLE OF CONTENTS TABLE OF CONTENTS

EF494T TM 06/2011 edition

2 DISASSEMBLY OF COMPONENTS

2.1 REMOVING THE ENGINE BONNET COVER

2.1.1 Removing/mounting the side covers

2.1.2 Removing the engine bonnet cover

2.2 REMOVING THE FENDER

2.2.1 Removing the fuel tank cover

2.2.2 Removing the nuts and bolts that fixing the fender

2.3 REMOVING THE STEP

2.4 REMOVING THE SEAT STAY

2.5 CLUTCH HOUSING

2.5.1 Separation

2.5.2 Docking

2.6 TRANSMISSION

2.6.1 Separating the hydraulic cylinder case

2.6.2 Separating the clutch housing and transmission

2.6.3 Rear axle

2.6.4 PTO module

2.7 FRONT AXLE UNIT

42 42

43 43

43 45 47

47 53

53 55 59 60

3 ENGINE

3.1 FUEL SYSTEM

3.1.1 Flow of fuel and layout of components

3.1.2 Water separator

3.1.3 Fuel feed pump

3.1.4 Fuel filter

3.1.5 Fuel injection pump (Type MP4 direct-injection

pump)

3.1.6 Fuel injection nozzles

3.2 COMBUSTION SYSTEM

3.2.1 Low emission technology applied to TNV engine

3.2.2 Cold starter

3.2.3 Revolution timer

3.2.4 Load timer

3.3 LUBRICATING OIL SYSTEM

3.3.1 Flow of lubricating oil

3.3.2 Lubrication oil pump (LO pump)

3.3.3 Lubricating oil filter (LO filter)

3.3.4 Oil pressure switch

65 66 66 66 66

68 70 71 71

72 73 74 74

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EF494T TM 06/2011 edition

iii

3.4 COOLING WATER SYSTEM

3.4.1 Flow of cooling water

3.4.2 Main components

3.4.3 Fuel injection pump

3.4.4 Piston

3.4.5 Checking pressures

3.4.6 Maintenance criteria

3.5 ADJUSTMENT SPECIFICATIONS

3.5.1 Engine adjustments

3.5.2 Cylinder head

3.5.3 Intake/exhaust valve and guide

3.5.4 Valve spring

3.5.5 Locker arm and shaft

3.5.6 Push rod

3.5.7 Camshaft

3.5.8 Idle gear shaft and bushing

3.5.9 Timing gear backlash

3.5.10 Cylinder block

3.5.11 Crankshaft

3.5.12 Thrust bearing

3.5.13 Piston

3.5.14 Piston rings

3.5.15 Connecting rod

3.5.16 Tappet

3.5.17 Lubricating oil pump (Trochoid pump)

3.5.18 Tightening torque tables

75 75 77 88 90 92

94 94 94 95 95 95 95 95 96 96 96 96 96 97 97 97 98 99

4 CLUTCH

100

4.1 STRUCTURE AND FUNCTIONS

4.1.1 Outline

4.2 DISASSEMBLY AND ASSEMBLY

4.2.1 Disassembly

4.2.2 Assembly

101

102

102 104

5 TRANMISSION

105

5.1 POWER TRANSMITTING DIAGRAM

5.2 TRANSMISSION SYSTEM CROSS-SECTION

5.3 TRANSMISSION SYSTEM

5.3.1 Main shift module

5.3.2 Reverse shift module

5.3.3 Range shift module

5.3.4 Front drive

5.3.5 PTO shift module

106 108

110

111 112 112 113

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TABLE OF CONTENTS TABLE OF CONTENTS

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5.4 TRANSMISSION (CLUTCH HOUSING CASE SIDE)

5.4.1 Disassembly

5.4.2 Main shift section

5.5 TRANSMISSION (TRANSMISSION HOUSING CASE SIDE)

5.5.1 Disassembly

5.5.2 PTO module

114

115

120

121

123 128

6 REAR AXLE AND BRAKE

130

6.1 STRUCTURE AND FUNCTIONS

6.1.1 Structure drawing

6.1.2 Differential system

6.1.3 Final drive system

6.1.4 Brake

6.2 DISASSEMBLY AND ASSEMBLY

6.2.1 Differential system

6.2.2 Rear axle oil seal

6.2.3 Planetary gears and axle shaft

131

131 132 133 134

136

136 137 138

7 FRONT AXLE

139

7.1 STRUCTURE AND FUNCTIONS

7.2 CROSS-SECTION VIEW

7.3 FRONT WHEEL ALIGNMENT

7.4 DISASSEMBLING THE FRONT BEARING CASE

7.5 DISASSEMBLING THE FRONT GEAR BOX

7.6 DISASSEMBLING AND ASSEMBLING THE FRONT DIFFERENTIAL SECTION

7.6.1 Disassembly

7.6.2 Assembly

140 141 142 143 143

144

144 146

8 POWER STEERING

148

8.1 STRUCTURE AND FUNCTIONS

8.1.1 Structure drawing

8.1.2 Hydraulic circuit

8.1.3 Power steering valve functions

8.1.4 Hydraulic pump

8.1.5 Power steering

8.2 POWER STEERING VALVE

8.2.1 Removing power steering valve assembly

8.2.2 Power steering relief pressure

8.2.3 Disassembly

149

149 150 151 152 153

154

154 155 156

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TABLE OF CONTENTS TABLE OF CONTENTS

EF494T TM 06/2011 edition

9 HYDRAULIC LIFT UNIT

159

9.1 STRUCTURE AND FUNCTIONS

9.1.1 Hydraulic line

9.1.2 Hydraulic cylinder case

9.1.3 Control valve

9.1.4 Relief valve

9.1.5 Safety valve

9.1.6 Stop valve

9.1.7 Hydraulic pump, exploded view

9.1.8 Position feedback link

9.1.9 Oil flow

9.1.10 Oil flow at Neutral

9.2 ASSEMBLY AND CHECK

9.2.1 Assembling/disassembling the control valve

9.2.2 Control valve, exploded view

9.2.3 Main relief pressure

9.2.4 Adjusting the position feedback rod

9.3 HYDRAULIC POWER TAKE OFF

9.3.1 For single action, pump trailer etc.

9.3.2 For double action, front blade etc.

9.3.3 Hydraulic pressure flow

160

160 161 162 162 163 163 164 165 167 170

172

172 173 174 175

176

176 177 178

10 ELECTRIC EQUIPMENT

182

10.1 ENGINE START CIRCUIT

10.1.1 Location and operation of components

10.1.2 Circuit diagram

10.1.3 Checkpoints of electrical equipment

10.2 CHARGING CIRCUIT

10.2.1 Location and operation of components

10.2.2 Circuit diagram

10.2.3 Checkpoints of electrical equipment

10.3 ALARM CIRCUIT

10.3.1 Location and operation of components

10.3.2 Circuit diagram

10.3.3 Checkpoints of electrical equipment

10.4 SAFETY CIRCUIT

10.4.1 Location and operation of components

10.4.2 Circuit diagram

10.4.3 Checkpoints of electrical equipment

183

183 186 187

192

192 193 194

195

195 197 198

200

200 203 204

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TABLE OF CONTENTS TABLE OF CONTENTS

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11 APEENDIXES

206

11.1 HYDRAULIC CIRCUIT DIAGRAM

11.2 ELECTRICAL DIAGRAM AND PARTS

11.2.1 WIRING HARNESS

11.2.2 LOCATION OF ELECTRICAL PARTS

11.2.3 ELECTRICAL WIRING DIAGRAM

207 208

208 209 210

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0 INTRODUCTION 0 INTRODUCTION

EF494T TM 06/2011 edition

0. INTRODUCTION

To the owner of this manual

 This machine is carefully designed and manufactured to give years of dependable service. To do

the better and safer job, read the instructions in this manual. Failure to do so could result in personal injury or machine damage.

 The parts used in this machine are subject to change to improve the quality and capacity of the

machine, and for safety.

 Therefore, please understand that the contents, photos and illustrations in the manual may differ

from your machine.

MAINTENANCE

When the machine is in abnormal condition, take the remedies. If the machine is still abnormal, ask Yanmar and give the following information:

 Machine model  Serial number  Detailed description of abnormal condition

SUPPLY PERIOD FOR MAINTENANCE PARTS

The period during which we supply maintenance parts for this machine is 9 years after we discontinue production of this machine. The supply of maintenance parts will, in principle, terminate at the end of the supply period stated above. However, even after the supply period has terminated, we still consult with you about the delivery time and the prices for parts still in stock, if required.

IMPROVEMENTS

To improve or upgrade the feature of the machine or for some other reason, parts are sometimes changed. In this case, parts of this manual may not apply to the machine.

The company has the right to improve or change when it becomes possible and practical to do so without incurring any obligations to make changes or additions to the equipment sold previously.

NOTE:

(1) All data are subject to alteration without notice. (2) Some photos, illustrations may not be identical with this machine due to improving or upgrading in

quality, performance or for some other reasons. Some illustrations and photos may show optional accessories.

(3) Right-hand (R.H.) and left-hand (L.H.) sides of this machine are determined by standing at the

rear of this machine and facing the direction of forward travel.

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SYMBOL INDICATION

1 Safety-alert Symbol

This is the safety-alert symbol. When you see this symbol on your tractor or in this manual, personal injury is possible or even likely if you do not follow the advice given. Read the messages that follow carefully.

2 Signal Words

The signal words "DANGER" "WARNING" "CAUTION" are used with the safety-alert symbol.

(1) "DANGER" indicates the extreme hazard

that would result in high probability of irreparable injury if proper precautions are not taken.

DANGER

(2) "WARNING" indicates the hazard that

would result in injury if proper precautions are not taken.

WARNING

(3) "CAUTION" indicates the general

precautions.

CAUTION

3 Service Instructions

(1) This stop symbol indicates an important

message about proper operation or service. When you see this symbol, read the message that follows carefully.

IMPORTANT

(2) NOTE describes precautions to take while

working.

NOTE

4 Measurements

This tractor is based on metric measurements. All hardware is therefore metric (ISO). Make sure to use the specified metric hardware when service is necessary.

5 Direction

The right and left sides of the tractor are determined by facing in the same direction as the tractor moves when going forward.

DIRECTION

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WARNING

You must carefully note the length of the bolts when you install Yanmar recommended implements and equipment behind the transmission case.

1. First, it is necessary to measure the thickness of the parts. Then use bolts whose length includes the extra measured thickness.

2. When the original part is removed and a different part is installed, it is necessary to measure difference in thickness of the two parts and change the length of the bolts appropriately.

If you don’t use appropriate consideration of these issues, you will damage the transmission case and create a dangerous situation.

Aluminum cases

Reference

The bolt length “B” in the case must be 2.0 times the diameter of “A”.

For casting metal cases, rear axles, etc., The bolt length “B” in the case must be 1.5 times the

diameter “A”. (D): Transmission case

Cast metal cases When you install part “a” behind the

transmission case, use bolts whose length includes measurement “C”.

CAUTION

 Do not try to adjust engine speed adjuster screw

(A) located on engine fuel injection pump. Any accident or failure resulting from adjusting the screw would not be covered by Yanmar's guarantee.

 Do not try to unseal and adjust engine fuel

injection pump (B). Any accident or failure resulting from adjusting the pump would not be covered by Yanmar's guarantee.

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0.1 PRECAUTIONS FOR THE SAFE SERVICES

DANGER SUFFICIENT VENTILATION Be sure to work in the well-ventilated place when the engine runs, welding or grinding a painted part.

[If not] Exhaust gas and paint dirt is poisonous and hazardous to human bodies.

CAUTION FLAT PLACE AND SUFFICIENT AREA The floor area should be sufficient, flat without holes at the service factory (place) to perform check and service work.

[If not] It may cause unexpected accidents such as falling down.

CAUTION CLEANED AND WELL ARRANGED PLACE Do not leave dust, mud, oil or any parts on the floor.

[If not] It may cause unexpected accidents.

CAUTION WELL AND SUFFICEINTLY LIGHTED PLACE A working place must have enough lighting. Use a portable safety light with cage when you work inside or under the machine.

[If not] The bulb may accidentally be broken and broken glass may cause injury or heat may cause fire.

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CAUTION KEEP A FIRE EXTINGUISHER AND FIRST AID KIT HANDY

 The workplace must be provided with a fire extinguisher.

Read instructions on the label to familiarize yourself with how to use it.

 Keep a first aid kit in a prescribed place.  Advise what to do in the event of fire or accidents.  Indicate who to contact in an emergency and keep their

telephone number in a prominent place.

CAUTION WEAR PROPER CLOTHING AND SAFETY ITEMS  Do not wear loose clothing or jewelry that can be caught

on the control levers and other machine parts. Also avoid wearing working clothes stained with oil as they can ignite.

 Be sure to wear a helmet, safety goggles, safety shoes,

a mask, gloves and other protective items, as appropriate. Take particular precautions when generating metal debris, when striking metal objects with a hammer or when cleaning components with compressed air.

 Also make sure there are no persons near the machine.

[If not] Moving part may catch, dust may get in eye, heavy part may drop on foot, etc. It may cause serious injury.

DANGER PROPER LIFTING AND SUPPORT When you work under the machine, support it firmly with such a crane, hoist or rigid racks on a level place.

[If not] It may cause severe accidents.

CAUTION PROPER TOOLS Using damaged or worn tools or using tools inappropriate for the required application is very dangerous, and may also cause damage to the machine. Make sure to use the tools that are appropriate for the specific job.

[If not] It may cause severe injury and/or damages on machine.

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CAUTION GENUINE PRODUCTS Be sure to use and install genuine products and spare parts.

[If not obeyed] It may cause unexpected failures and shorten the machine life span.

WARNING TIGHTEN BOLTS AND NUTS WITH THE SPECIFIED TORQUE Be sure to tighten bolts and nuts with the specified torque in this manual.

[If not] Bolts or nuts may be loosen or drop. It may cause breakdown of components and/or injury.

WARNING AVOID SHORT-CIRCUITING Be sure to disconnect the (-) terminal of battery before servicing.

[If not] Short circuit may cause a fire.

WARNING CHARGING BATTERY Keep a battery away from the fire while charging. Gas from battery electrolyte is flammable and explosive.

[If not] It may explode or cause fire.

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WARNING HANDLING BATTERY ELECTROLYTE The battery electrolyte is diluted sulfuric acid and poisonous. Refill battery electrolyte in well ventilated area and wear eye protection and rubber gloves.

[If not] Splashed solution can cause burning skin, cloths and blindness if it get into eyes.

DANGER KEEP FUEL AND OIL AWAY FROM SOURCES OF IGNITION  Open flames can ignite fuel, oil, hydraulic oil or

antifreeze solutions, which are flammable and dangerous.

Special attention must be paid to the following matters.  Keep flammable materials away from lighted cigarettes

or matches, or any other sources of ignition.

 Never refuel while the engine is running. Smoking

during refueling must be strictly prohibited.

 Firmly tighten the caps on the fuel and oil tanks.  Store fuel and oil in a cool and well-ventilated place

where they are not subjected to direct sunlight.

 Fuel and oil must be stored in a place which meets all

applicable safety regulations. Unauthorized persons should not be allowed entry.

DANGER PROVIDE ADEQUATE VENTILATION WHEN WORKING IN AN ENCLOSED AREA Engine exhaust fumes are harmful to the human body and their inhalation is extremely hazardous. When starting the engine in an enclosed area, open the windows and doors for ventilation. Also do not idle the engine unnecessarily or leave the engine running while the machine is not in use.

DANGER REMOVED ATTACHMENTS When an attachment is placed on the ground or against a wall after removing it or prior to reinstalling it, be sure that it is stable to prevent it from falling down.

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DANGER WORKING UNDER THE MACHINE  Before performing service or repairs underneath the

machine, place the implement on the ground in its lowest position.

 Be sure to apply blocks to the tracks to lock the tracks

securely.

 Never perform service underneath the machine if it is

not completely stable.

DANGER RADIATOR COOLING WATER LEVEL  Before checking the radiator cooling water level, stop

the engine and wait until the engine and the radiator have cooled down.

 Slowly loosen the cap to release the inner pressure

before removing the cap.

WARNING BE CAREFUL OF HOT OIL UNDER HIGH-PRESSURE  Hydraulic fluid escaping under pressure can have

sufficient force to penetrate the skin and do serious damage and that immediate medical assistance be sought.

 The hydraulic system for the implement operates under

high pressure.

 When replenishing or draining hydraulic oil, be sure to

first relieve the high pressure.

 The emission of hot oil under high-pressure from a small

leak could result in serious bodily injury.

 Wear safety goggles and thick gloves when checking for

leaks. Use a piece of cardboard or a plywood block to detect emissions of hot oil.

 If the hot oil should contact your body, obtain prompt

medical treatment.

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WARNING BE CAREFUL WHEN SERVICING SYSTEMS UNDER HIGH TEMPERATURE AND HIGH PRESSURE The engine cooling water and each lube oil system are still under high temperature and pressure immediately after the engine has stopped. Removing caps, draining oil and water, or replacing filter elements at that time may cause a burn. Wait until the temperature drops, then begin servicing in accordance with the procedures described in this manual.

WARNING ROTATING RADIATOR FAN AND FAN BELT  Never contact the rotating radiator fan or fan belt with

any object.

 Contacting the rotating radiator fan or fan belt with any

object can result in serious bodily injury.

CAUTION ALWAYS BE ENVIRONMENTALLY RESPONSIBLE  Follow the guidelines of the governmental agency for

the proper disposal of hazardous materials such as engine oil, diesel fuel, engine coolant and, machine fluid, grease.

 NEVER dispose of hazardous materials irresponsibly by

dumping them into a sewer, on the ground, or into groundwater or waterways.

 Failure to follow these procedures may seriously harm

the environment.

 Comply with legal regulations and guidelines for

disposal of: empty containers for fuel, cooling water (coolant), oil, grease; fuel/oil filters; batteries; machine itself; machine accessories; and packaging materials.

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WARNING INFLATING TIRE When you inflate tire, use long hose with self-attaching air chuck for not standing in front of or over tire. Use safe cage if available. Do not inflate tire beyond maximum recommended pressure in operator's manual.

[If not] An over-inflated tire can explode and cause injury or death.

WARNING

MOUNT/DISMOUNT TIRE Do not attempt to mount or dismount tire unless you have proper equipment and experience. Follow proper procedure when mounting or dismounting tire on wheel or rim.

[If not]

It may cause explosion and may cause injury.

WARNING

RIM OR RIM PARTS Do not cut or weld on rim or rim parts. Do not use damaged rims. If rim is damaged, replace it. Do not replace rims with anything but a genuine or a part of proper size, type and quality. Always deflate tire before removing spikes or other objects from tire carcass.

[If not] Damaged rim may cause an explosion.

AFTER SERVICING THE MACHINE MAKE SURE TO:

a) Retighten all removed fasteners, bolts and nuts to specified torque. b) Reinstall all safety shields and devices removed during service. c) Refill radiator coolant, hydraulic oil, engine oil, etc. which are drained during service with approved

or recommended fluid.

d) Start the engine and check for leaks. Operate all controls and make sure tractor and implements

are functioning properly. After testing, shut down the engine and check the work you performed (any missing cotter pins, washers, locknuts, etc.) Recheck all fluid levels again.

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0 INTRODUCTION 0 INTRODUCTION

EF494T TM 06/2011 edition

0.2 AFTER SALES SERVICE

After sales service

If your tractor is not working normally, refer to the troubleshooting section in this manual. You can also consult with your service representative.

Information needed when asking for service:  Model name and serial number (A) of your

tractor.

 Engine type number (B)  Operating conditions. What type of work was

being performed when the problem occurred?

 How long have you used your tractor? (total

hours of operation)

 Any other information about the problem that has

occurred.

Availability of spare parts

Maintenance parts and spare parts will be available for 10 years after the production of this tractor series has been discontinued. However, special parts will be available subject to consultation. Yanmar may be able to supply a particular part after the normal supply period.

(A) Tractor serial number (B) Engine type number

(A)

(B)

PURPOSE OF THIS MACHINE

This machine is designed to be operated with a various implement for particular tasks and for pulling a trailer in a variety of agricultural operations. Other use or modification is prohibited.

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EF494T TM 06/2011 edition

0.3 GENERAL PRECAUTIONS FOR SERVICES

0.3.1 GENERAL

When contacting us about your machine identify it with the model and serial numbers of the tractor and its engine, and the usage hours displayed on the hour meter.

Hour meter

The hour meter numerically indicates the operating hours of the tractor. The indicated number is used to determine when to check the engine oil and other similar consumables. (The hour meter starts counting when the engine is started.)

(A) Hour meter

WARNING Prior to disassembly or reassembly, disconnect battery cable (A) from the negative port (B) to prevent short circuit. To separate the transmission, be sure to lock the front axle with the wedge (B) to prevent it from swinging.

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EF494T TM 06/2011 edition

To replace components, always use the Yanmar genuine parts. Be sure to replace packing and O-ring with new one. Apply the grease slightly on O-ring and oil seal prior to install.

To install a snap ring, place the edged side in the direction that the force is loaded as the right figure shows.

(A) External sanp ring (B) Internal snap ring (C) Arrow indicates force direction

To drive in a spring pin (spring pin), place the split part (mating part) in the direction that the force is loaded as the right figure shows.

Force in axial direction

Force in rotating direction

Once you remove a split pin, replace the split pin with a new one and split it surely.

As for a thrust washer with grooves, pay attention to the assembling direction.

(A) Oil groove (B) Thrust washer

To connect or disconnect coupler (connector) of electric parts harness, be sure to switch off the starter switch.

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EF494T TM 06/2011 edition

0.3.2 USAGE OF THE LIQUID GASKET

Pare off sealing material on the surface with a scraper. Do not to scratch or damage on the mating surface. If the surface gets scratch or damage, correct them by grinding with oilstone.

(A) Scraper

1. Wipe the oil or dirt from the mating surface with

a wiper dipped in cleaning solvent. Oil must be removed completely.

 Do not use kerosene or diesel oil.

2. Cut the applying nozzle as the bead width of

squeezed liquid gasket is 3 to 3.5 mm. Set a squeezing tool if available.

 Do not level the applied liquid gasket with a

finger or a spatula. It may cause incomplete sealing.

3. When the liquid gasket is supposed to be

applied around a bolt hole, apply it inner side of the mating surface.

4. Assemble mating surfaces within 15 minutes

after applying liquid gasket.

5. Tighten all bolts lightly and tighten them further

till specified tightening torque is obtained. The bolts must be tightened diagonally.

6. Wait for more than 30 minutes after assembly to

fill up lubricating oil or operate.

Apply liquid gasket

Within 15 minutes

Assembly

Leave for 30 minutes or longer.

Lubrication, operation

 Be sure to follow the specified time or it could

cause leakage.

(A) Liquid gasket (B) Bad (C) Good (D) Hole for bolt

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EF494T TM 06/2011 edition

1. When using the liquid gasket again after a tube

is opened, the gasket in the nozzle part may have been hardened or deteriorated. Squeeze out the liquid gasket a little and then use it.

2. When the surface of squeezed out liquid gasket

glitters, it means the filler (oil) is separated and the gasket is deteriorated.

 It sometimes is found the oil of liquid gasket is

separated within the period of validity. It is not deteriorated.

 Normal gasket will be hardened in about 2

hours, but the deteriorated gasket would not be hardened.

(A) When liquid gasket is deteriorated, oil

is separated from components.

(B) Squeeze out about 20 mm and check

deterioration.

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0.3.3 SCREW TIGHTENING TORQUE TABLE

Tighten screws, bolts and nuts according to the table below. If the tightening torque is specified, follow the specification.

General tightening torque Unit: N-m (kgf-m)

Items

Thread diameter

Tightening torque

PT plug

1/8

9.8 (1.0)

1/4

19.6 (2.0)

3/8

29.4 (3.0)

1/2

58.8 (6.0)

Pipe joint bolt

13.0 - 16.4 (1.3 - 1.7)

M12

24.5 - 34.3 (2.5 - 3.5)

M14

39.2 - 49.0 (4.0 - 5.0)

M16

49.0 - 58.8 (5.0 - 6.0)

General tightening torque of bolts N-m (kgf-m)

Standard thread screw

Nominal size

4.90 - 6.86 (0.5 - 0.7)

8 - 12 (0.8 - 1.2)

12.74 - 16.66 (1.3 - 1.7)

23 - 29 (2.3 - 3.0)

M10

24.50 - 34.36 (2.5 - 3.5)

44 - 59 (4.5 - 6.0)

M12

44.10 - 58.80 (4.5 - 6.0)

78 - 98 (8.0 - 10.0)

M14

68.80 - 83.30 (7.0 - 8.5)

118 - 147 (12.0 - 15.0)

M16

107.80 - 137.20 (11.0 - 14.0)

167 - 206 (17.0 - 21.0)

M18

156.80 - 186.20 (16.0 - 19.0)

235 - 284 (24.0 - 29.0)

M20

215.60 - 264.60 (22.0 - 27.0)

324 - 402 (33.0 - 41.0)

IMPORTANT

 The tightening torque of fine thread screws shall be 80% of that of the standard thread

screws.

 To tighten any aluminum part, apply torque equivalent to 80% of the specified value.  Recently, all the bolts may be standardized to 7T bolts under the plant line management of

Yanmar.

 When 7T bolt is used with rubber, rubber packing or aluminum parts, tighten the bolt

following the values in the 4T-bolt table.

Bolt standard

Tensile Strength (kgf/sq.mm)

Minimum

Brinell Hardness (Hb)

Minimum

105

201

Maximum

229

277

Yield Point (kgf/sq.mm)

Minimum

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0.3.4 FUSE BOX

(1) The alternator and main fuses are 60A, slow-

blow fuses.

(A) Alternator fuse: 60A (B) Main fuse: 60A

(2) The electrical fuses are in the engine

compartment.

START : Starter motor 5A WORK : Working light 5A TURN : Turn signal light 5A TAIL : Tail light 5A HEAD : Head light 15A HORN : Horn 5A FUEL : Fuel pump 5A ENG : Timer relay 5A IND : Indicator light 5A

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0.3.5 PART NAMES

(1) Bonnet (2) Headlights (3) Side lens (4) Front axle bracket (5) Front tires (6) Steering wheel (7) Safety frame (ROPS) (8) Tail lamp (9) Fuel tank

(10) Rear tire (11) Hydraulic stop-slow return valve (12) Step (13) Operator’s seat (14) Top link (15) Lower link (16) PTO shift lever (17) Flasher lamp (Side marker lamps) (18) Rear fender

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(1) Light switch, Horn switch, Flasher switch (2) Reverser lever (3) Clutch pedal (4) Parking brake lever (5) Operator's seat adjusting lever (6) Range shift lever (7) Front wheel drive lever (8) Seat belt

(9) Main switch

(10) Accelerator lever (11) Main shift lever (12) Brake pedal (13) Accelerator pedal (14) Differential lock pedal (15) Position control lever

(16) Hydraulic stop slow return valve (17) PTO shift lever

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0.3.6 SAFETY LABEL LOCATION

(1) Label, Brake coupling (2) Label, CAUTION (3) Label, Fire caution (4) Label, Danger shaft rotate (5) Label, Thailand only

(6) Label, Tractor ID (7) Label, Engine ID

(on the engine)

(8) Label, Caution muffler (9) Label, Safety cover

(10) Label, ROPS ID (11) Label, ROPS safety (12) Label, Seat belt (13) Label, speed (14) Label, PTO shaft lever

(1) 198283-65360

(2) 198283-65310

(3) 198283-65250

(4) 198163-65350

(5) 198283-65651

(6)

(7) (8) 198163-65930

(10)

(11) 1A7680-65350

(12) 1A7680-65910

(9) 198163-65940

(14) 1A6150-93151

(13) 1A7781-65560

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0.3.7 SPECIFICATIONS

Model

EF494T

Drive type

4-wheel Drive

Dimensions

Overall length (mm)

3,230

Overall width (mm)

1,605

Overall height (mm)

2,355 (ROPS)

Wheelbase (mm)

1,830

Tread

Front (mm)

1,300, 1,466

Rear (mm)

1,270, 1,352

Ground clearance (mm)

375

Weight (kg)

1,540

Engine

Model

4TNV88

Type

4-cycle, water-cooled diesel

Output (SAE Gross) (HP/rpm)

49/2,800

Number of cylinders

Bore x Stroke (mm)

88 x 90

Displacement (cc)

2,189

Air cleaner

Dry, dual element

Fuel tank capacity (liter)

Battery

12V-52AH

Steering

Hydrostatic

Clutch

Dry, single

Brake

Mechanical, wet disc

Transmission

Type

Collar shift

Gear shift (Forward x Reverse)

F9 x R9

Forward speed (km/hr)

1.6-28.8

Reverses speed (km/hr)

1.7-29.7

Max. speed, forward (km/hr)

30.8

Tire

Front

8-18-6

Rear

13.6-26-8

Rear PTO

Type

Transmission PTO

PTO shaft

SAE1-3/8 inch (35mm), 6 spline

Speed (rpm)

568, 769 at rated engine speed

Hydraulic

Type

Position control

Hitch

3 point hitch, category SAE #1

Draw bar hitch

Clevis type

NOTE:

All technical data, measurement and weight are approximate, and the manufacturer has the right to make alteration without prior notice.

0.3.8 TRACTOR MASS AND TIRE SPECIFICATION

TIRE SIZE

(Number of plies)

FRONT AXLE

REAR AXLE

Maximum working load of tires

Technically permissible mass on each axle

Maximum working load of tires

Technically permissible mass on each axle

F: 8-18(6), R: 13.6-26(8)

650

980

1,580

1,675

IMPORTANT Set up the implement so that the front wheel load and the rear wheel load are not greater than the smaller of the following: the permissible load capacity of the tires or the technically permissible mass on each axle.

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PERIODICAL INSPECTION

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1.1 CHECK INTERVALS

x: Checks required

CHECK ITEMS

50 h

100h

150h

200h

250h

300h

350h

400h

450h

500h

550h

600h

Engine lubrication oil

Replace

Engine oil element

Replace

Transmission oil

Replace

x x x

Replace

x x x x x

Replace

Line filter (Hydraulic)

Replace

Transmission oil strainer

Clean

Fuel filter

Replace

Water separator element

Drain

Clean Drain

Drain

Clean

Radiator interior

Clean the interior of radiator when replacing cooling water

Cooling water

Check before every work / Replacing every year

Front axle oil

Replace

x x x

Replace

x x x x x

Replace

Air cleaner element

x x x x x

Replace

x x x x x

Replace

Radiator screen

x x x x x x x x x x x

Clean cooling fan, radiator

x x x x x x x x x x x

Battery liquid level

Check before every work

Battery liquid gravity

x x x x x

Fuel piping, connections

x x x x x x x x x x x

Rubber hoses (Power steering)

x x x x x x x x x x x

Radiator hoses

Replace hoses every 2 years

Hydraulic rubber hoses

Replace hoses every 2 years

Fuel pipe, electric wires

Replace pipes and wires every 2 years

Electric wiring, connections

x x x x x x x x x x x

Greasing

x x x x x x x x x x x

Greasing, propeller shaft

Apply

Fastening of steering wheel fix nut

x x x x x

Important nuts and bolts

x x x x x x

Cooling fan belt

x x x x x x

Engine breather pipe

x x x x x x x x x x x

Engine crank case

Clearance of exhaust valve

Fuel injection valve

Generator, start motor

x x x x

Hydraulic system

x x x x

Break-in period is 50 hours. If not reached, take up 1 year instead. Items marked "Replace" should be replaced every 2 years even before suggested time intervals. Replace the power steering hoses every 2 years.

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1.2 OIL AND GREASE

OIL, GREASE

Type

Fuel

Diesel fuel only

Engine oil

SAE 30 or 40 API Grade CD or better

YES-EO

Grease

Multipurpose Grease

Transmission oil, Hydraulic system oil

TF-500 Transmission fluid

YES-HO

* At temperature below – 10°C, use Super No.3 light oil.

1.3 OIL AND WATER VOLUME

Capacity (liters)

Oil type

Fuel

Diesel light oil

Cooling

Radiator

Anti-rusting fluid

water

Sub-tank

0.45

Anti-rusting fluid

Engine oil

5.3

YES-EO, SAE #30 or #40, API Grade CD or better

Transmission oil

TF-500A Transmission fluid, YES-HO

Front axle oil

7.5

TF-500A Transmission fluid, YES-HO, SAE#90

1.4 EQUIVALENT TO TF-500

Supplier

Brand name

Mobil

Mobil Fluid 425, 424

Castrol

Agricastrol MP, CASTROL UTF

Shell

Tellus Oil 32 or 37, Donax TD

Ford

ESN-M-2C-134A

Esso

Torque Fluid 56

John Deere

J20B, J14A

Tractran UTH

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1.5 REPLACING OIL

DANGER Never add oil while the engine is warm or running. A fire may occur.

CAUTION Never add oil just after stopping the engine. You may be burned.

Engine oil Check

Draw out the dipstick on the right side of the engine and wipe off oil with a cloth. Reinsert and remove it again to see if the oil level is within the upper and lower marks.

If insufficient, add the new oil as much as the normal level through the supply port.

(A) Dipstick (B) Oil supply port

NOTE:

Check the oil level before the engine starts or when the engine is cool.

Never check oil level immediately after engine stop. Oil is in various places and it may show insufficient level. Wait for more that 20 minutes after engine stop and check oil level.

(A) Dipstick (a) Upper limit (b) Lower limit (c) Specified level zone

Replacing oil

Remove remaining oil through the drain plug on the lower part of the engine. Add the new oil through the oil supply port. Select a proper type of engine oil and replace it periodically considering the temperature and operating conditions.

(A) Drain plug

Replace: First 50 hrs, then every 100 hrs. Capacity: 5.3 litters Type: SAE#30-40, YES-EO, API grade CD or better

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Transmission oil Check

Draw out the dipstick on the rear part of the transmission and check the oil level. The level should be between the upper and lower limits. If insufficient, add the new oil to the normal level. Also check for leaks.

(A) Dipstick (a) Upper limit (b) Lower limit (c) Specified level zone

(A) Oil supply port (B) Dipstick

Replacing oil

Remove the remaining oil through the drain plugs on the bottom of the transmission case. Removal is easy if the transmission case is warm. Add the new oil through the supply port on the rear part.

 Transmission oil is commonly used with

hydraulic oil and power steering oil.

 Use Yanmar transmission fluid TF-500 or

equivalent for transmission oil.

(A) Drain plug

Replace: First 50 hrs, then every 300 hrs. Capacity: 27 litters Type: TF500, YES-HO or equivalent

Cleaning transmission oil strainer

When replace transmission oil, wash the oil strainer with diesel fuel.

(A) Oil strainer

Equivalent to TF-500A

Supplier

Brand name

Mobil

Mobil Fluid 425, 424

Castrol

Agricastrol MP, CASTROL UTF

Shell

Tellus Oil 32 or 37, Donax TD

Ford

ESN-M-2C-134A

Esso

Torque Fluid 56

John Deere

J20B, J14A

Tractran UTH

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Front axle oil Check

Remove the dipstick plug on the top of the front axle. Wipe off the gauge rod and reinsert it without screwing. Redraw it and see if the oil level is within the upper and lower marks. If insufficient, add the new oil through the oil supply port to the normal level. Check also for oil leak.

(A) Dipstick (a) Upper limit (b) Lower limit (c) Specified level zone

(A) Dipstick plug (B) Oil supply port

Replacing oil

Remove oil through center drain plug on the lower part of the front axle and drain plugs on the bottom of the right and left gear cases. Add oil through the right port.

Use Yanmar transmission fluid TF-500A or equivalent for front axle oil.

(A) Center drain plug (B) Gear case R drain plug (C) Gear case L drain plug

Replace: First 50 hrs, then every 300 hrs. Capacity: 7.5 litters Type: TF500, YES-HO or SAE#90

1.6 REPLACING FILTER ELEMENTS

Engine oil element

Replace engine oil element first 50 hours and then every 300 hours or every 2-3 times of replacing the engine oil.

Replacing

(1) Remove engine oil and turn the cartridge

anticlockwise with a filter wrench.

(2) Apply a little oil on the rubber ring on the new

cartridge. Mount the cartridge by hand first and tight it with filter wrench.

(3) After replacing the engine oil, run the engine

until oil pressure pilot lamp goes off.

(4) When oil pressure lamp goes off, stop engine

and wait for more than 20 minutes. Check the oil level and if insufficient, add the oil.

(A) Turn left to detach (B) Oil element

NOTE: Use genuine element. Otherwise, it may cause trouble in the engine

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Line filter (Transmission oil element)

The line filter is of a cartridge type. Replace it with a new one first 50 hours and then every 300 hours.

Replacing

(1) Remove the transmission oil and remove the

cartridge by turning anticlockwise.

(2) Apply a little oil on the rubber ring on the new

cartridge. Mount the cartridge by hand first and tight it with filter wrench.

(3) After replacing the transmission oil, idle the

engine and check the oil level with dipstick. If insufficient, add the oil.

(A) Line filter

NOTE: Use genuine element. Otherwise, it may cause trouble in the engine

Fuel filter element Replace fuel filter every 300 hours. Replacing

(1) Close fuel cock on water separator. (2) Remove the cartridge by turning anticlockwise. (3) Apply a little oil on the rubber ring on the new

cartridge. Mount the cartridge by hand first and tight it with filter wrench.

(4) Open the cock and bleed the air from the fuel.

NOTE: Use genuine element. Otherwise, FIE (Fuel Injection Pump) will be in trouble, premature wearing of plunger.

(A) Fuel filter

1.7 REPLACING COOLING WATER

DANGER Never open the radiator cap when the radiator is hot. You may be burned by the hot vapor.

Check

Open the bonnet and right side cover of the engine and check if the sub tank water is within the upper and lower limit marks. If insufficient, add water through the supply port.

(A) Sub tank (B) Supply port

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Replacing

(1) Remove the radiator cap and the drain plug

(A) to drain off the engine cooling water.

(2) Clean the radiator with tap water until dust or

rust is all drained out.

• It is suggested to use radiator detergent. Run engine in idling speed for more than 15 minutes and remove the water.

(3) Put drain plug and add anti-rusting fluid

fallowing the instruction of fluid. Fill fresh water until it overflows.

(4) Put radiator cap and start the engine to mix

the anti-rusting fluid with fresh water.

NOTE:

 When the new cooling water has been added,

never fail to put anti-rusting fluid and run engine in idling speed for about 5 minutes to ensure mixing.

 For mixing ratio of anti-rusting fluid, fallow the

instruction of Manufacturer of fluid.

 When cooling water level becomes low, add only

fresh water.

(A) Radiator drain plug

1.8 REMOVING WATER FROM WATER SEPARATOR

The water separator is mounted on the lower part of the fuel tank. When the red O-ring comes up, put the fuel cock in the C position and detach the transparent case. Then, remove water.

Clean water separator every 300 hours and drain water every 50 hours. If strainer was damaged, replace it.

(a) Open (b) Close

(A) Water separator

Cleaning water separator strainer

(1) Turn fuel cock to (b), in the C (Close) position. (2) Turn retaining ring (E) to loosen, remove ring

and detach water separator bowl. (3) Clean strainer, inside of bowl. (4) Reinstall strainer, bowl and retaining ring. (5) Turn fuel cock to (a) to open the fuel cock, in the

O (open).

NOTE:

Strainer is made of plastic and be careful not to damage. It is suggested to clean it with used toothbrush or soft brush. If strainer was damaged, replace it with new genuine part.

(A) Water separator (B) Fuel cock (C) Strainer (D) Drain cock (E) Retaining ring

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1.9 CLEANING AND REPLACING AIR

CLEANER ELEMENT, CLEANING RADIATOR SCREEN

The air cleaner serves to keep the engine in favorable conditions by removing dust in air and preventing the cylinder liner and piston ring from wearing.

For operation in a dusty environment, clean the air cleaner element every 50 hours and replace it every 300 hours.

For operation in a normal condition, clean it every 100 hours and replace it every 1000 hours. Even before the said intervals, replace it every year.

IMPORTANT

Never remove inner element (B). This element avoids from getting dust into engine while cleaning outer element (A). When the inner element (B) is broken or very dirty, replace it. It cannot be cleaned.

(A) Air cleaner (Outer)

(B) Air cleaner (Inner)

Cleaning air cleaner element

(1) Open the bonnet. (2) Remove the sub tank. (3) Open the lid and take out the element (A).

Never remove inner element (B).

(4) Blow air from inside of the element or lightly

pat it to take off dust. Be careful not to damage the fins.

Cleaning radiator screen

Pull the radiator screen upward and remove straws and dust from it.

(A) Radiator screen

NOTE:

When removing radiator screen and cleaning radiator fin together, be careful not to damage radiator fins. Radiator fins are very soft and if damaged, it may cause water leak or lower cooling efficiency.

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1.10 CHECKING BATTERY

DANGER

 Never use a fire while checking the battery or the

battery cap is removed. Otherwise, a fire or gas

explosion may result.  Do not touch battery electrolyte with bare hand. If the

electrolyte is spilled on your body or cloth, wash it out

immediately with water. Electrolyte may cause a burn.

CAUTION To connect battery, start with the positive terminal (+) first, For removal, remove negative terminal (-) first. Otherwise, short-circuit may cause fire.

Check battery

Check the level of battery electrolyte whether it is between upper and lower limit line. If the level is lower than the lower limit, add distilled water as high as the upper limit.

(A) Battery (B) Upper limit (C) Lower limit

NOTE:

 Excessive battery electrolyte may overflow during

recharging, damaging the metallic parts of the tractor.

 Add distilled water only. Adding battery electrolyte,

such dilute sulfuric acid, may shorten the battery life.

 Quick charge is not recommended.  When replacing the battery, use the specified battery.

IMPORTANT

 Make sure the tractor is level when checking the level

of electrolyte.

Removing and installing battery

Remove

(1) Open the bonnet (2) Disconnect the negative (ground) cable from the

battery and disconnect the positive cable.

(3) Loosen fixing nuts and remove the battery.

Installation

(1) Connect positive cable and negative cable. (2) Tighten fixing nut.

(D) Negative (ground) cable (E) Positive cable (F) Fixing nut

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IMPORTANT

 Be sure the tractor is level when checking electrolyte

level.

 When connecting the battery cables, wipe oil away

from the terminal contacts. After connecting cables, apply grease to the terminals.

 Be sure to attach the rubber boots for the positive

terminal of the battery.

 When replacing the battery, be sure to use a genuine

or equivalent battery specified in the right table.

 For environmental protection and recycle of

resources, return the old battery fallowing the regulation of your place.

Battery type

Specified battery

Parts code No.

75D26R

1A7781-51510

Voltage

12Volts

Capacity 5HR

52AH

Charging rate

11 Amperes

1.11 CHECKING HOSE AND PIPE

CAUTION Aged or damaged hose or pipe causes leak. Leak may cause fire if it is fuel. If damaged, replace it with new one.

Check the power steering pipes, fuel pipes and radiator hoses for leak or loose couplings. Replace them every 2 years.

(A) Radiator hose (B) Fuel pipe (C) Power steering pipes

NOTE:

Bleed the air when a fuel pipe is replaced.

1.12 CHECKING ELECTRICAL WIRING

WARNING  Check before starting day's work that the cables are

not short circuit to other parts or insulator is not damaged, or contacts are not loosened.

 Remove straws and dust from the cables and joints

before starting works. Otherwise, a short circuit can cause a fire.

Remove the engine side covers and check the electrical wires for damaged sheaths or loose connections. Repair them or consult your service representative.

Check them every 50 hours and replace them every year whether damaged or not damaged.

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1.13 GREASING

Before initiating day's work, check the greasing condition at each point. Grease up after a work on a muddy field. As a general rule, grease up various points at intervals of 50 hours.

(A) Brake pedal shaft (B) Clutch pedal (C) Tie rod end (D) Power steering rod end (E) Center pin (front and rear) (F) Lift link, right

NOTE: Power steering rod ends are modified and no greasing is required from S/N 000530.

(A)

(A), (B)

(C)

(C), (D)

(E)

(F)

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Lubricating propeller shaft with grease

Lubricate the propeller shaft connection with grease every 500 hr. When working in the wet field, shorter lubrication intervals are suggested.

1. Front end

(1) Loosen the band (A). (2) Remove the bolt (B) and the collar (C). (3) Slide the front shaft cover (D) backward as the

right picture shows.

(A) Band (B) Bolt (C) Collar (D) Front shaft cover

(4) Turn over the rubber boots (E) as the right

illustration shows.

(5) Slide the coupling (F) backward as the right

illustration shows.

※Be careful not to lose ball (G).

(6) Apply enough multipurpose grease to six balls

(G).

(7) Turn back the rubber boots (E) to their original

position.

(8) Fix the front shaft cover (D) to front axle support

with bolt (B) and collar (C).

※Be sure to install collar (C). If not, the front

shaft cover may be broken in a short time.

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2. Rear end

(1) Remove the bolt (B) and collar (C) from rear

shaft cover (H).

(2) Slide the rear shaft cover (H) backward as the

right picture shows.

(3) Turn over the rubber boots (E) as the right

illustration shows.

(4) Slide the coupling (F) frontward as the right

illustration shows.

※Be careful not to lose ball (G).

(5) Apply enough multipurpose Grease to six balls

(G).

(6) Turn back rubber boots (E) to their original

position.

(7) Fix the rear shaft cover (H) with bolt (B) and

collar (C).

※ Be sure to install the collar (C). If not, the rear

shaft cover may be broken in a short time.

(8) Tighten the band (A).

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1.14 ADJUSTING BRAKE

WARNING

 Check if the brake is effective or not one-sided.

An accident can result.

 Unbalanced play at left and right brake pedals

can cause one-sided braking effect. Keep the same amount of play; otherwise, an accident can result.

Depress the brake to see a required play of 30-40 mm is available and if the left and right pedals work together. If not, adjust the turnbuckles behind the pedals for a play of 30 mm. Secure the turnbuckle with the lock nuts. Make sure the parking brake lock is put on when the brake pedals are fully stepped in.

(A) Play 30-40 mm (B) Turn buckle

Right brake

Left brake

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1.15 ADJUSTING CLUTCH

Standard version Depress the clutch pedal to see it there is a specified play of 15-25 mm. It not, adjust the turnbuckle for a play of 15-25 mm. Securely lock the nut after adjustment.

(A) Play 15-25 mm (B) Turn buckle

1.16 ADJUSTING STEERING WHEEL

WARNING Check a play for the steering wheel. It should be within a tolerable range. Otherwise, an accident may occur.

Turn the steering wheel slightly left and right to see if there is a play of 20-50 mm. Improper play will fail to provide the smoothness and linearity of steering function. If a play is not adequate, contact your service representative.

(A) Play

NOTE: Steering free play is not adjustable due to hydrostatic power steering. When free play comes more, the wearing of tie rod end, power steering rod end and/or center pin may have caused it. If so, replace it immediately.

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1.17 ADJUSTING FAN BELT

CAUTION Wait until the engine is sufficiently cooled down. Otherwise, you may be burned.

(1) Switch off the engine. (2) Open the bonnet, then the left side cover of

the engine.

(3) Press the fan belt with a finger at the midpoint

to see the belt deflections 10-15 mm.

(4) If not, loosen the alternator fastening bolt and

shift the alternator to adjust the belt tension.

If the belt still slips after full shift of the alternator, replace the belt with a new one. Check the new belt at intervals of 50 hours.

(A) Alternator (B) Alternator fastening bolts (C) Fan belt

1.18 ADJUSTING TOW-IN

Poor adjustment of tow-in will result in an abnormal steering performance. Measure the front wheel dimension “a” and “b”. The difference of “a-b” should be 4-8 mm. If out of this range, loosen the lock nut of the tie rod end and adjust the turnbuckle. Fasten the lock nut where the tow-in is 4-8 mm.

(F) Forward (R) Rearward a: distance between the center of tires, rear b: distance between the center of tires, front

(B) Tie rod (C) Lock nut

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1.19 REPLACING FUSE

Remove the lid of the fuse box and check the fuse. Replace the blown fuse with new one. Stop the engine and check the main fuse (slow blow fuse) which shuts off the electrical circuit when an excessive current flows. Fused condition can be checked by the changed color of the outer sheath.

(A) Fuse box

Slow Blow Fuse (A) Main fuse: 60A

(B) Alternator fuse: 60A

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1.20 CHECKING TIRES

Adjust the air pressure of front and rear tires to the standard pressure. Check the tires for cracks or damage. Adjust the front tire pressure for a maximum in the following table if a load is to be imposed on the front tires through the front weight or front loader.

Air pressure (kg/cm2)

Front tire 2.4 (34 lb/sq.in) Rear tire 2.0 (28.4 lb/sq.in)

Fastening torque

Fixing bolts for wheel and axle shaft:

186 N-m (19 kgf-m, 137 lb-ft)

Excessive Standard Insufficient

1.21 COLOR OF EXHAUST GAS

The color of exhaust gas is black when the engine is started and gray during normal operation.

Black: Incomplete combustion due to dense fuel White: Engine oil is burning. Normal exhaust may

look white at extremely low temperature.

If exhaust gas is black or white without a load on the tractor, consult your service representative.

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DISASSEMBLY OF COMPONENTS

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EF494T TM 06/2011 edition

2.1 REMOVING THE ENGINE BONNET COVER

2.1.1 Removing/mounting the side covers <Removing>

(1) Open the bonnet. (2) Put the locking knobs in the vertical position

(each forward and rear).

(3) Remove the side covers.

(1) Clamp the cover lower hooks (x 2). (2) Fix the cover top with the locking knob.

2.1.2 Removing the engine bonnet cover

Remove the 3 bolts (A) and the pin (B), and remove the engine bonnet cover.

CAUTION This work should be done by 2 people. If you work alone, you may be injured.

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2.2 REMOVING THE FENDER

2.2.1 Removing the fuel tank cover

(A) Fuel tank cover (B) Bolt M8x16, 7pieces.

Note:

Pay attention to the electrical wiring.

2.2.2 Removing the nuts and bolts that fixing

the fender

Note:

 Be careful not to lose the rubber washers (A) or

the collars (B).

 The fender can be removed without removing

the rear tire.

2.3 REMOVING THE STEP

(1) Remove the 2 screws (A), the three M6x20

bolts (B), and pull the front column cover (D). Then, disconnect key switch coupler.

(2) Remove the four M6x20 bolts (A), and remove

the cover (B).

Note:

Be careful not to lose the rubber washers and the collars.

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(3) Remove the 4 mounting pins (D), and remove

the right floor (C). Remove the left floor following the same sequence of right side floor.

(4) Remove the three M8x20 bolts (A), and

remove the right floor stay.

IMPORTANT

The entire parking brake assembly can be removed. Remember the relative positions of the various parts.

(5) Remove the two M8x20 bolts (A) that fix oil

filter, the four M8x20 bolts (B), and then remove left floor stay.

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2.4 REMOVING THE SEAT STAY

Note:

It is necessary to remove the fuel tank.

(1) Remove the seat, lever knobs (A), and

housing cover (B) (M6x16: 8 pieces.).

(B)

(2) Remove fender.

Refer “2.2 REMOVING THE FENDER”.

(3) Drain the fuel from the fuel tank. Fuel can be

drained easily from section (A).

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(4) Remove the return pipe (A) from the fuel tank,

and disconnect coupler to fuel gauge (B) located in section C. Then, remove the bolts (D).

CAUTION The rubber packing (A) is used when installing the fuel tank. Be sure to reinstall it when reassembling the tractor.

(5) Slide the fuel tank upward to remove it.

After removing the tank

(6) Remove the differential gear lock pedal return

spring (A) from the seat stay, transmission breather (B), and then the piping and wiring clamps (C) and (D).

(7) Remove the four M8x16 bolts (E) and the two

M8x25 bolts on the back of the seat, and remove the seat stay.

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2.5 CLUTCH HOUSING

2.5.1 Separation

(1) Place chocks at front and rear wheels.

Disconnect battery. Insert wedges (A) to the

left and right of the front axle swing section.

WARNING Be sure to insert the wedges. If not, engine would tilt when clutch housing is separated and front axle section might turn over. It may cause serious injury.

(2) Remove the M8x12 bolts, (B), front and rear

that fixing propeller shaft cover. Loosen clam of rubber boots on the center of shaft cover and slide front cover rearward.

(3) Remove the 4.0x40 cotter pin (A). Move

propeller shaft coupling (B) rearward and remove propeller shaft with covers.

WARNING Since the propeller shaft is heavy. Be careful so that you are not injured if the shaft falls when removing it.

(B)

IMPORTANT

 When installing the cotter pin (A), be sure to

replace it with a new one.

 Be careful not to lose the 6 steel balls (B) each,

on the front and rear of the propeller shaft.

 Before reinstalling the rubber boots (C), put

grease in them.

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(4) Remove the following parts from the left side

of the machine.

(A) (B) Low-pressure hydraulic pipes (C) High-pressure hydraulic pipe: M6 Bolts x 4

pieces. (D) Generator wirings (E) Electric wire clamps: 3 places (F) Hydraulic pipe fixing bolts under clutch housing

(5) Remove the following parts from the upper

part of the engine. (A) Water temperature meter wire

(B) Engine speed and revolution cable

(6) Disconnect the battery cable from the

negative terminal to prevent short circuit. (A) Battery cable

(B) Battery terminal, negative (-)

(7) Remove the following parts from the right

side of the machine. (A) Wire clamps

(B) Power steering cylinder pipes (C) Fuel hose (D) Engine oil pressure switch coupler (E) Fuel feed pump coupler (G) Relay coupler (H) Head lamp coupler (I) Body earth (ground)

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(8) Remove bonnet.

See “2.1 REMOVING THE ENGINE

BONNET COVER”.

(9) Remove the front column cover (A) and the

dashboard cover (B).

(10) Remove bonnet stay fixing bolt (A), air cut

plate (air deflection plate) fixing bolts (B), and

hydraulic pipe fixing bolt (C).

(11) Remove the accelerator lever assembly (A)

and the air cut plate (air deflection plate) (D). (A) Accelerator lever assembly

(B) Accelerator links (C) Fixing bolts (D) Air cut plate

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(12) Remove the following parts from the power

steering valve. (A) Pipe from the hydraulic pump (High pressure)

(B) Return pipe (Low pressure)

IMPORTANT

 When the clutch housing section is separated

without removing the pipes (A) and (B), the pipes could get caught in the starter and be destroyed.

 When removing the pipes (A) and (B),

remember the position they were in, in order to reassemble them correctly.

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(13) Remove the bolt (A), M12 x 34, on rear end

and upper of front axle bracket, left and right

sides. Install lifting bolt on left and right

sides, as shown in the photo.

Lifting bolt Bolt size: Dia. 12mm

DANGER

 Screw the lifting bolt all the way into the engine

block side.

 When reinstalling the bolt after

reassembling, tighten it securely to the torque specified below. 167-186 N-m, 17.0-19.0 kgf-m, 123-137 lb-ft

IMPORTANT

 If a short lifting bolt is used, the lifting rope may

touch peripheral equipment on the engine and some damage could occur.

 Do not jack up the engine oil pan. The oil pan

may deform and this can cause oil leaks.

(14) Place the jack under the transmission (B),

and raise the jack until the jack is lightly

supporting the transmission.

(15) Lift the engine section to hold original height

or slightly higher.

IMPORTANT

If the engine section is lifted too much, it may damage or deform parts.

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(16) Remove nuts and bolts that connect engine

and clutch housing. (A) Bolt M12x30: 3 pieces.

(B) Bolt M12x170: 2 pieces. (C) Bolt M12x100: 2 pieces. (D) Nut M12: 1 pc.

(17) Separate the engine and the clutch housing.

Note:

If clutch housing adhered to engine by liquid gasket too strongly, place a piece of wood as right photo shows and push or tap on it lightly. It will be easy to separate them.

WARNING Be careful transmission not to come off supporting jack. This operation should be done by at least 2 people.

IMPORTANT

After separating, put a rigid stand to section A and remove the lifting bolt. If not, the lifting bolt may be deformed and you may not be able to remove it.

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2.5.2 Docking

(1) Remove the old liquid gasket on mating

surface of engine and clutch housing. Apply Three bond 1215 or equivalent type of liquid gasket.

WARNING The disassembled machine is very unstable. Be careful not to let it fall over and be sure to attach a wedge to the front axle swing section.

IMPORTANT

If clutch and pressure plate was disassembled, align clutch disc as described in “4 Clutch” in this manual.

(2) Move the main shift lever to N and the PTO

to the shift position. Dock the machine by turning the rear axle PTO shaft by hand. Note: The shaft is docked to the clutch plate when the PTO shaft does not turn any more.

(3) Move the main shift lever and the sub-shift

lever to ON. Insert a screwdriver though the view port on the flywheel and complete the docking procedure by turning the flywheel.

(4) After docking the machine, reinstall the parts

by reversing the procedure described in

“2.5.1 Separation”.

View port on the flywheel

2.6 TRANSMISSION

2.6.1 Separating the hydraulic cylinder case

(1) Remove the seat stay. See “2.4 REMOVING

THE SEAT STAY”.

(2) Remove the bolt (A), and disconnect the

hydraulic pipe.

IMPORTANT

Replace the copper packing with a new one.

(3) Remove the 12 pieces of M12x35 bolts (B).

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(4) Raise the lift arms (A) and the stopper & slow

return valve section (B), and then separate the hydraulic cylinder case.

WARNING It should be done by at least 2 people because hydraulic cylinder case is heavy.

IMPORTANT

Two positioning pins are used between the transmission case and the hydraulic cylinder case. When you push the lift arms (A) up from the bottom, the pins will come off and the hydraulic cylinder case can be separated easily.

(5) Keep the hydraulic cylinder case upright, as

shown in the photo, so that the mating surface is not damaged.

IMPORTANT

Completely remove the packing located between the transmission case and the hydraulic cylinder case.

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2.6.2 Separating the clutch housing and

transmission

WARNING The disassembled machine is very unstable. Be careful not to let it fall over.

(1) Drain the transmission oil. (2) Remove the step. See 2.3. (3) Remove the seat stay. See 2.4. (4) Remove the propeller shaft. See 2.5.1 (2) (3). (5) Remove the front column cover and the

dashboard. See 2.5.1 (9).

(6) Remove the bolts (A) in order to take out the

oil filter. Then, remove the left step stays (B) and (C). At the same time, remove the lowpressure hydraulic pipe at section D.

IMPORTANT

The clutch pedal return spring (E) must be installed in the correct direction.

Note:

When the clutch rod (F) is new, it will curve as shown in the photo. This is normal.

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(7) Remove the right step stays (A) and (B), and

remove the left and right brake rods (C).

(G) Separation position

IMPORTANT

The brake pedal return springs (D) must be installed in the correct directions.

Note:

Remember the position of the parking brake (E).

(8) Remove the fuel pipe at section A, and

remove the 4 pipe clips (B).

(9) Remove the coupler to the PTO neutral

switch on the rear end of the transmission.

IMPORTANT

Remember the route the harness follows.

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(10) Remove the high-pressure pipe (A). (11) Move the reverser lever to the neutral

position, and remove the reverser rod (A).

IMPORTANT

Before removing the reverser rod, be sure that the reverser lever is in the neutral position.

(12) Remove the nut (B) and pull the reverser (C)

change arm out about 15 mm.

(13) Attach a support to the front and back at the

separation point.

Note:

When the front section is lifted, the preferred position is shown in the photo.

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(14) Remove the four M12 bolts (A) and the 2 nuts

(B), and separate the clutch housing and the transmission slowly.

CAUTION This operation should be done by at least 2 people.

IMPORTANT

Before joining the clutch housing and the transmission, remove the old packing (C) completely, and use a new one.

Note:

If the engine section has already been separated, separate the clutch housing and the transmission as shown in the photo. However, pass a lifting rope through the steering wheel to prevent it from turning over.

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2.6.3 Rear axle Disassembling the rear axle housing

(1) Drain the transmission oil. (2) Remove the fender seat and rear (3) Remove the 3-point link. (4) Remove the roll guard. (5) Remove the rear wheels. (jack set as

well)

(6) Remove the brake rod. (7) Remove the rear axle housing fixing

bolts.

Be careful not to drop the friction plate

and the steel brake plate.

Left and right side

9: Bolt M12 x 40 x 8 pcs. 10: Bolt M12 x 50 x 2 pcs.

Left side only

4: Nut M10x 2 pcs. 5: Stud M10x90x2 pcs.

Right side only

11: Bolt M10x85x2 pcs.

Rear axle housing fixing bolts allocation

Tightening torque

Rear axle housing

M10: 450-600 kgf-cm M12: 800-1000 kgf-cm

Rear wheel

M16: 1800-2000 kgf-cm

Axle housing and transmission case bolt

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2.6.4 PTO module Removing PTO covers

(1) Drain the transmission oil. (2) Remove the 3-point link. (3) Remove the draw-bar hitch and braw-bar

bracket.

(4) Set the PTO to first or second gear. (5) Remove the keeper plate and pull the shift

arm out of the PTO shift module.

NOTE: If the PTO is left in the neutral position, the

PTO safety switch and the shift arm will hit

each other and the shift arm cannot be

pulled out.

(6) Remove the rear cover bolts and separate

the PTO assembly.

Tightening torque: 230-300 kgf-cm

(A) Shift arm (B) Keeper plate (C) PTO safety switch

IMPORTANT

 Pay attention to the clearance between the

change arm and the PTO safety switch.

 Push the change arm (C) into the PTO

module groove (A) to reassemble them. After reassembly, move the PTO shift lever and make sure you can change gears.

(B) PTO safety switch (C) Change arm

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2.7 FRONT AXLE UNIT

(1) Drain the oil from the front axle. (2) Remove the propeller shaft. See 2.5.1 (2) (3).

(A) Propeller shaft

(3) Remove the power steering hose (B). (4) It loosens bolts of the front wheels. (5) Jack up the front part of the tractor and

take out front wheels.

(6) Set the jack or the support under the front

axle.

(7) Remove 4 bolts (A) and take out the center

pins (B). Then the front axle is separated

from the tractor.

WARNING When removing the center pins, be careful that the front axle does not topple forward or backward.

IMPORTANT

Adjustment shims are included.

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(1) Jack up the front axle, after that insert the

center pin, and tighten 2 bolts. Then, check the free play of the front axle to be 0-0.6 mm adjusted by shims.

Apply threadlocker (Loctite) on bolt thread.

(A) Shims (B) Oil seal (C) Center pin (D) Tighten torque : 118-132 N-m

(12.0-13.5 kgf-m, 87-97 lb-ft)

(E) Free play of axle to be 0-0.6 mm adjusted by

shims.

(F) Enclose grease. The injection entrance to be

assembled downward.

DANGER Apply thread locker (Loctite) on the bolt (D). If you don't, it may cause the central pin to come off and this is dangerous.

IMPORTANT

 When reassembling the front axle unit on a

new tractor

 When raising and lowering the front wheels

while jacked-up, make sure the front axle swings smoothly.

 If there is no free play, the front axle will be

too stiff.

During maintenance The number of shims counted during disassembly is only an indication. When the spacer (C) is worn, it will be necessary to reduce the number of shims.

(A) Adjust shim (B) Shim (C) Spacer

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(2) Reinstall the front wheels, lower the jack,

and tighten the wheel bolts.

IMPORTANT

Wheel bolt torque 177-196 N-m (18.0-20.0 kgf-m, 130-145 lb-ft)

(3) Reinstall the propeller shaft and shaft cover.

IMPORTANT

 Put grease into the rubber boots on both

sides.

 Replace the split pin (B) with a new one.  There are 6 steel balls (C) on each side.  Be sure to install spacer (E) on rear and front

side. If not, cover may be broken in a short time.



(A) Mounting bolt (B) Split pin (C) Steel balls

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(D) Rubber boots (E) Spacer 

(4) Connect the pipe to the power steering

cylinder.

(5) Supply oil to the front axle. 

 

ENGINE

3.1 FUEL SYSTEM

3.1.1 Flow of fuel and layout of

components

 



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(1) Fuel tank (2) Water separator (3) Fuel feed pump(4) Fuel filter (4) Fuel filter (5) Fuel injection pump(6) High-pressure tubes (6) High-pressure tubes (7) Injection nozzles(A) Feed (A) Feed

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(B) Return

(3) Reinstall the propeller shaft and shaft cover.

IMPORTANT

 Put grease into the rubber boots on both

sides.

 Replace the split pin (B) with a new one.  There are 6 steel balls (C) on each side.  Be sure to install spacer (E) on rear and front

side. If not, cover may be broken in a short time.



(A) Mounting bolt (B) Split pin (C) Steel balls (D) Rubber boots (E) Spacer 

(4) Connect the pipe to the power steering

cylinder.

(5) Supply oil to the front axle. 

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 

ENGINE

(3) Reinstall the propeller shaft and shaft cover.

IMPORTANT

 Put grease into the rubber boots on both

sides.

 Replace the split pin (B) with a new one.  There are 6 steel balls (C) on each side.  Be sure to install spacer (E) on rear and front

side. If not, cover may be broken in a short time.



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EF494T TM 06/2011 edition

(A) Mounting bolt (B) Split pin (C) Steel balls (D) Rubber boots (E) Spacer 

(4) Connect the pipe to the power steering

cylinder.

(5) Supply oil to the front axle. 

 

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(3) Reinstall the propeller shaft and shaft cover.

IMPORTANT

 Put grease into the rubber boots on both

sides.

 Replace the split pin (B) with a new one.  There are 6 steel balls (C) on each side.  Be sure to install spacer (E) on rear and front

side. If not, cover may be broken in a short time.



(A) Mounting bolt (B) Split pin (C) Steel balls (D) Rubber boots (E) Spacer 

(4) Connect the pipe to the power steering

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EF494T TM 06/2011 edition

cylinder.

(5) Supply oil to the front axle. 

 

(3) Reinstall the propeller shaft and shaft cover.

IMPORTANT

 Put grease into the rubber boots on both

sides.

 Replace the split pin (B) with a new one.  There are 6 steel balls (C) on each side.  Be sure to install spacer (E) on rear and front

side. If not, cover may be broken in a short time.



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EF494T TM 06/2011 edition

(A) Mounting bolt (B) Split pin (C) Steel balls (D) Rubber boots (E) Spacer 

(4) Connect the pipe to the power steering

cylinder.

(5) Supply oil to the front axle. 

 

(3) Reinstall the propeller shaft and shaft cover.

IMPORTANT

 Put grease into the rubber boots on both

sides.

 Replace the split pin (B) with a new one.  There are 6 steel balls (C) on each side.  Be sure to install spacer (E) on rear and front

side. If not, cover may be broken in a short time.



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EF494T TM 06/2011 edition

(A) Mounting bolt (B) Split pin (C) Steel balls (D) Rubber boots (E) Spacer 

(4) Connect the pipe to the power steering

cylinder.

(5) Supply oil to the front axle. 

 

(3) Reinstall the propeller shaft and shaft cover.

IMPORTANT

 Put grease into the rubber boots on both

sides.

 Replace the split pin (B) with a new one.  There are 6 steel balls (C) on each side.  Be sure to install spacer (E) on rear and front

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side. If not, cover may be broken in a short time.



(A) Mounting bolt (B) Split pin (C) Steel balls (D) Rubber boots (E) Spacer 

(4) Connect the pipe to the power steering

cylinder.

(5) Supply oil to the front axle. 

 

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(3) Reinstall the propeller shaft and shaft cover.

IMPORTANT

 Put grease into the rubber boots on both

sides.

 Replace the split pin (B) with a new one.  There are 6 steel balls (C) on each side.  Be sure to install spacer (E) on rear and front

side. If not, cover may be broken in a short time.



(A) Mounting bolt (B) Split pin (C) Steel balls (D) Rubber boots (E) Spacer 

(4) Connect the pipe to the power steering

cylinder.

(5) Supply oil to the front axle. 

 

(3) Reinstall the propeller shaft and shaft cover.

IMPORTANT

 Put grease into the rubber boots on both

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sides.

 Replace the split pin (B) with a new one.  There are 6 steel balls (C) on each side.  Be sure to install spacer (E) on rear and front

side. If not, cover may be broken in a short time.



(A) Mounting bolt (B) Split pin (C) Steel balls (D) Rubber boots (E) Spacer 

(4) Connect the pipe to the power steering

cylinder.

(5) Supply oil to the front axle. 



(3) Reinstall the propeller shaft and shaft cover.

IMPORTANT

 Put grease into the rubber boots on both

sides.

 Replace the split pin (B) with a new one.  There are 6 steel balls (C) on each side.  Be sure to install spacer (E) on rear and front

side. If not, cover may be broken in a short time.



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(A) Mounting bolt (B) Split pin (C) Steel balls (D) Rubber boots (E) Spacer 

(4) Connect the pipe to the power steering

cylinder.

(5) Supply oil to the front axle. 



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ENGINE

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3.1 FUEL SYSTEM

3.1.1 Flow of fuel and layout of

components

 

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(B) Return

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3.1.2 Water separator

Eliminates contaminants, sediments and water from the fuel to prevent them from entering the fuel feed pump.

[C] Close [O] Open (A) Water separator (B) Fuel cock (C) Drain cock

 



Cleaning the water separator

Move the fuel cock to position C (close) and loosen the cup mounting screws. Clean strainer and related parts. Open the cock to bleed out the air.

Drain water: every 50 hr Cleaning: every 300hr, shorter is preferable

IMPORTANT

When the water indicator ring (A) is floating up, should clean the water separator as soon as possible. If not, it would cause trouble of fuel injection pump, such premature wearing.

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

(A) Water indicator ring

3.1.3 Fuel feed pump

Draws the fuel from the fuel tank and delivers it to the fuel injection pump.

(A) Fuel feed pump

3.1.4 Fuel filter

Removes foreign particles from the fuel to prevent them from entering the fuel injection pump.

Replacement intervalEvery 300 operating hours or 6 months, whichever is earlier Every 300 operating hours or 6 months, whichever is earlier 

(B) Fuel filter

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 

Replacement intervalEvery 300 operating hours or 6 months, whichever is earlier Every 300 operating hours or 6 months, whichever is earlier 

(B) Fuel filter

Replacement intervalEvery 300 operating hours or 6 months, whichever is earlier Every 300 operating hours or 6 months, whichever is earlier 

(B) Fuel filter

Replacement intervalEvery 300 operating hours or 6 months, whichever is earlier Every 300 operating hours or 6 months, whichever is earlier 

(B) Fuel filter

Replacement intervalEvery 300 operating hours or 6 months, whichever is earlier Every 300 operating hours or 6 months, whichever is earlier 

(B) Fuel filter

Replacement intervalEvery 300 operating hours or 6 months, whichever is earlier Every 300 operating hours or 6 months, whichever is earlier 

(B) Fuel filter

Replacement intervalEvery 300 operating hours or 6 months, whichever is earlier Every 300 operating hours or 6 months, whichever is earlier 

(B) Fuel filter

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Replacement intervalEvery 300 operating hours or 6 months, whichever is earlier Every 300 operating hours or 6 months, whichever is earlier

(B) Fuel filter 



3.1.5 Fuel

injection pump (Type MP4 directinjection pump)

A mono-plunger pump where, in response to the signal from the actuator of the Eco-governor, a pinion rotates the plunger to adjust the relative positions of the plunger notch and the fuel port, thereby controlling the fuel injection quantity.

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3.1.6 Fuel injection nozzles

The use of Yanmar's original direct-injection combustion chamber plus hole valve ensures the ideal mixing of fuel with air, thereby enabling complete combustion.

Combustion chamber

Direct-injection type

Nozzle

Hole valve (5 injection holes)

Initial injection pressure

21.6MPa (220kg/cm2)

(1) The nuts and case nuts used to assemble the fuel injection valve should be

tightened to the specified torque.

Tightening torque

Mounting bolt for fuel injection valve retainer(M8 x 1.25)

24.4 to 28.4N•m (2.3 to 2.9kgf•m) Case nut

39 to 44N•m (4 to 4.5kgf•m)

Note: Do not lubricate the bolt threads and the nut face. (2) When removing the injection valve, make sure that protector (A) and packing

(B) do not remain in the cylinder head. Replace them whenever reinstalling the injection valve.

(3) An increase of 0.1 mm in thickness of the pressure adjusting shim section will

result in an increase of about 19 MPa in injection pressure.

IMPORTANT

 When the install the fuel injection nozzle, apply the molybdenum grease to the

outside of the (D).

 The flat surface of the washer (C) must be faced upward.

(A) Protector (B) Packing (C) Washer (D) Nozzle holder

(E) Pressure adjusting

shim section (F) Nozzle spring (G) Nozzle spring seat

(H) Valve stop spacer (I) Nozzle valve (J) Nozzle body

(K) Nozzle (L) Nozzle mounting nut Tightening torque: 39 –

44 N•m (4 – 4.5 kgf•m)

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3.2 COMBUSTION SYSTEM

3.2.1 Low emission technology applied to

TNV engine

<Fuel injection technology> (1) MP4 pump

 Atomization by high-pressure injection (70

MPa)  Injection timing optimized by using a multi-

functional timer mechanism

<Fuel injection technology> (2) New type nozzle

Increased number of nozzle hoes (5 nozzle holes) Finer atomization by making the nozzle hole diameter smaller Uniform injection by rounding the edge of each nozzle hole

(A) Nozzle for TNV engine (R) Rounded inlet of nozzle hole

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<Emission control technology> (3) : The TNV engine features 2 intake valves and

2 exhaust valves per cylinder. The fuel directinjection valve is of vertical type and is center located and the combustion chamber is located at the center of the cylinder, thereby enabling a decrease in emission of PM and NOx.

< Fuel technology > (4) Intake and exhaust

 Swirl ratio optimized by redesigning the intake

port  Air-fuel mixture optimized by reviewing the

compression ratio

Combustion chamber

 Air-fuel mixture optimized by using a new

combustion chamber  Uniform injection achieved by reviewing the

nozzle mounting angle (locating it at the

center of the combustion chamber)

(A) Injection nozzle (B) Combustion chamber (C) Piston

Three new mechanisms of the MP4 pump

The mono-plunger type fuel pump uses a single plunger to distribute fuel uniformly to each cylinder, thereby eliminating the variation in fuel distribution between the cylinders. Fuel is atomized by highpressure injection and the fuel timing at each engine speed and load condition is optimized by using a revolution timer and a load timer. This has achieved clean exhaust and high-efficient combustion performance. The new TNV diesel engine ensures low fuel consumption and high eco-friendliness.

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3.2.2 Cold starter

The injection timing at cold start is made earlier to improve startability. The piston of the cold starter is operated by the CSD solenoid valve depending upon the temperature of cooling water for the engine, thereby opening/closing the sub-port.

At hot start:

The sub-port is open and the plunger blocks the sub-port. In this state, fuel starts being pumped. Hot start assumes a temperature of about 5°C minimum.

(A) (When sub-port is open) Sub-port (B) Start pumping (C) Main port (D) CSD valve (E) Piston (F) Barrel (G) Plunger (H) Hot state (About 5°C minimum)

At cold start:

The sub-port is closed and the plunger blocks the main port. In this state, fuel starts being pumped. (At cold start, the fuel injection timing is advanced.) Cold start assumes a temperature of about 5°C maximum.

(A) (When sub-port is closed) Sub-port (B) Start pumping (C) Main port (D) CSD valve (E) Piston (F) Barrel (G) Plunger (H) Cold state (About 5°C maximum)

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3.2.3 Revolution timer

Clean exhaust gas is assured over the entire range of engine speeds by changing the fuel injection timing according to the engine speed.

At low engine speed

Fuel injection is less affected by the viscosity of fuel and starts after the sub-port has been closed. (At a low engine speed, the injection timing is delayed.)

At high engine speed

Fuel injection is affected by the viscosity of fuel and starts even if the sub-port is not closed.

(A) Low (B) Engine rpm (C) High (D) Delay (E) Timing (F) Advance (G) Sub-port (H) Plunger (I) Main port (J) Load timer

3.2.4 Load timer

The fuel injection timing is changed in accordance with the load condition of the engine, thereby optimizing the injection timing over the entire range from the no-load condition to the fullload condition and making exhaust gas clean.

When the upper leading part of the plunger goes beyond the main port, fuel injection starts. Once load is applied, the plunger starts operating and the stroke length of the upper part of the plunger increases. The fuel injection timing is delayed accordingly. (The injection timing is delayed when load is applied.)

(A) Upper leading part (B) Main port (C) Fuel (D) Main leading part (E) Plunger (F) Fuel increase (G) Fuel decrease (H) Load increase (I) The injection timing is delayed and the stroke length of the upper leading part increases as the load increases.

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3.3 LUBRICATING OIL SYSTEM

3.3.1 Flow of lubricating oil

The oil in the oil pan passes through the strainer, is sucked up by the lubricating oil pump, and then lubricates the interior of the engine block and cylinder head through the oil filter and cooler.

(A) Oil filter (B) Strainer

(E) Hydraulic pressure switch

(A) Relief valve (bypass) (B) Lubricating oil filter (C) Regulator (D) Lubricating oil pump (E) Lubricating oil filter (F) Cylinder body (G) Main gallery (H) Hydraulic switch (I) Fuel injection pump (J) Intermediate gear shaft (K) Gear shaft (L) Cam bearing (M) Valve arm pin (N) Valve arm (O) Tappet-cam face (P) Crank journal (Q) Crank pin (R) Injection nozzle (S) Piston (T) Oil pan

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(A) Fuel injection pump (B) Hydraulic switch activation

Pressure (0.5±0.1 kg/cm2) (C) Blancer shaft (D) Oil circuit

(E) Valve arm shaft (F) Camshaft (G) Crankshaft (H) Filter

(I) Pump (J) Strainer (K) Oil filter(secondary) (L) Oil pump

3.3.2 Lubrication oil pump (LO pump)

A trochoid pump installed on the cylinder block, driven by a crank gear, and provided with a relief valve to protect the oil cooler.

Discharge pressure (at rated rpm)

0.44 MPa (4.5 kgf/cm2)

(A) Crank gear (B) Cranks shaft (C) Cover (D) Relief valve (E) Spring (F) Plug (G) Outer rotor (H) Inner rotor (Driven by crank gear) (I) Gear case

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3.3.3 Lubricating oil filter (LO filter)

Has a built-in bypass valve in case of blockage. The vale will be activated at a differential pressure of 1.0 0.2 kgf/cm2 across the paper filter element and enable the oil to flow through the bypass circuit.

(A) Oil filter (a) Rubber packing (b) Bypass valve (safety valve) Activation pressure: 0.6 kgf/cm2 (Low idling

RPM) (c) Lubricating oil pump (d) Lubricating oil (e) Paper filter element (f) Normal flow path (g) Bypass flow path

3.3.4 Oil pressure switch

Closes to provide an alarm (illuminate an alarm LED on the combination meter) when the lubricating oil pressure decreases to a certain limit.

(A) Oil pressure switch

Yanmar EF-494T Service Manual

Specifications and Main Features

Frequently Asked Questions

User Manual