Yanmar YM155d, YM135d Service Manual

1
MAKING EFFECTIVE
USE
OF
THIS SERVICE MANUAL
This manual discusses the maintenance standards and
ed
from the standpoint of the repairman, in order that the tractor can perform in top condition
through correct servicing procedures.
Repairs conducted by estimations or force of habit could lead to unexpected accidents and seri-
ous trouble. Always carry out repairs in
=
SERIAL NUMBERS
Do not limit your work merely to the actual repair work alone but always strive to carry out dependable servicing, including such efforts and keeping maintenance records.
In order to easily process any claims parts be clearly written on the prescribed form, and then sent to the dealer for forwarding to the manufacturer.
a
scientific and accurate manner.
as
noting down the servicing history of your tractor
it
is imperative that the full details and serial numbers of
/p,&s-
Drive

CONTENTS

I
.
Nomenclature
.
I
I
Specifications
1
.
Specifications
2
Power train Power train (1)
Power train Power train Power train
3
.
Transmission sectional view
4
.
Electric wiring diagram
.
Fuel system
5 6
.
Engine lubricating system
.
Cooling system
7
.
Transmission lubelhydraulic system
8
Ill
.
Tractor separation
IV . .Disassembly sequence V . Engine disassembly VI . Engine construction and maintenance
1
.
Cylinder liners 35
.
Pinons
2
.
Piston rings
3
.
Piston pin
4
.
Connecting rods
5
.
Crankshaft
6
.
7
Camshaft 43 8 . Cylinder head 45 9
.
Combustion chambers
10 . Rocker arm assembly 11 . Injection pump and injection valve
12
Governor
13 . Lubricating oil pump
.
14 Cwling system 15 . Gears
16. Oil seals. O-rings and ball bearings
VII . Engine assembly VI
I I
.
1
.
Governor linkage
2
Valve clearance
3
.
Fuel injection timing
.
Fan belt tension
4
.
Air venting (bleeding)
5 6 . Other measurements and inspections
IX . Electrical equipment
1
.
Battev
2
.
Governor & current limiter
.....................
....................
....................
....................
.....................
Engine adjustments
.....................
................
.................
..................
...................
.................
(2)
.................
(3)
.................
(4)
.................
...........
............
...................
............
.................
.....
.............
............
.............
.................
..................
................
...................
.................
.............
..............
.......
..............
.................
.......
...............
............
................
.................
..............
................
..............
......
............
...........
.
10 10 11 12 13 14 15
17 17 18 18
19
20 31 35
36
37
38
39
40
46 48 48
53
53
54
54
54
55 61
61 61
62 63 63
64
65
65 67
5
5
1
3
.
Inspection and characteristics
4 . Cautions during handling and assembly 5 . Instructions for disassembly and assembly
6 . Maintenance and inspection
7
.
Starter motor
.
Thermostart (optional)
8
.
9 Turn signal lights (optional) 77
10
.
Water temperature indicator light 11 . Engine lube oil pressure 12 . Horn
.
13
.
74
X . Tractor construction and maintenance
1
.
2
3 . Brake
.
4 5 . Steering
.
6
XI . Tractorassembly
1
.
2
2-10 Reversellst speed shift shaft
2-1 1
2-12 Gear shaft lever assembly 2-13 P.T.O. reduction shaft assembly 2-14 Connecting shaft assembly 2-15 P.T.O. shaft assembly 2-16 Differential lock shaft 2-17
2-18 Differential device 120, 2-18 (a) Disassembly
2-18 2-19 Cam
......................
Lights
Safety start switch
Clutch and relevant items
Transmission and related items
......................
Hydraulic lift device
Front axle and rear axle
General assembly Transmission assembly
2-1 P.T.O. driving shaft assembly 2-2
'P.T.o.
2-3 Front P.T.O. shaft assembly
(YM135D . YM155D)
2-4 Front P.T.O. shift shaft assembly
(YM135D . YM155D) 2-5 Driven shaft assembly 2-6 Counter shaft assembly 2-7 Low-high shift shaft assembly 2-8 Main change shaft assembly 2-9 The fork of the
shaft assembly
assembly
Main shaft and transmission front
cover assembly
Final reduction pinion and rear
axle shaft assembly 118
(b) Assembly
..................
.....................
...............
..............
.....................
..............
...............
fork shaft assembly
2ndl3rd speed shift
.............
................
.............
.............
...............
.
differential lock assembly
..........
.....
...
...........
.............
...........
........
.............
............
.........
.............
............
......
.......
..........
..........
..........
.........
......
.......
........
.....
.......
..........
aisembly
.....
...........
...........
.....
.
69 70
71 a1
72 78
78
.
79
89
90
93 95
103
103­105
105 106
107
107 108 109 110 110
Ill
112
113 114 115 115 116 117
12 122
122
77
77 78 78
79
83
3 . Front axle assembly
3-1 Front axle assembly (YM155D
YM135D)
3-2
Front axle assembly (YM155. YM135)
3-3 Front axle assembly (YM155D.
.
YM135Dl
3-4
Differential device assembly (YM155D
YM135D. front axle)
4 . Center pin assembly
4-1 For YM155D & YM135D
4-2 For YM155 & YM135 5 . Brake drum assembly 6 . Hydraulic system assembly
6.1 Cylinder head assembly
62 Lifting shaft.
hydraulic piston rod assembly
6-3 Control valve assembly
6-4
Hydraulic control fork. hydraulic
control lever assembly
6-5 Auto-return rod. operator's seat
bracket assembly
6-6 Slow return valve assembly
n
6-7 Lift arm assembly
68
Operational precaution polnts
.............
.
................
...............
..........
.............
.......
.........
.............
..........
.........
lift
arms.
liff
crank.
.....
.........
.........
............
.......
............
.....
.
.
XI1 . Tractor adjustments
XI
II
.
Tractor trouble-shooting
1 . Engine and related items
2
Electrical system
.
Brake system
3 4
.
Clutch and related item
5
.
Transmission and related items
6
.
P.T.O.
and related items
7
.
Hydraulic system
8
.
Steering and suspension system
XIV . Regular inspections XV . Tightening torque ratings
XVI
.
Maintenance equipment and tools
.................
...............
...........
...........
...............
...........
...........
...........
........
.......
.......
.......
.
.
141
142
143 145 745 746 147 147 148
149
150 151 153
I.

NOMENCLATURE

Model
YM135
(1) Muffler
(2) Brake pedal (31 Step
(4) Differential lock pedal (5) Instrument panel
(6)
Drag rod
(7)
Knuckle arm (8) Bumper (9) Battery
(101 Radiator (111 Hood (12) Engine (13) Air cleaner (14) Fuel tank (15) Throttle lever (16) Steering wheel (17) Gear shift lever
P.T.O.
(18)
(19) Hydraulic control lever (20) Assist bar
)
(21 (22) Fender
(23) Lift link
shift lever
Operator's seat
Model
YM155
(24) Top link (25) Top link hinge
(26)
P.T.O. shaft
(27)
Lower link (28) Lift arm (29) Rear tire (30) Rear wheel (31 ) Brake (32) Transmission case (33) Brake rod (34) Pitman arm (35) Range
..
-
shift . lever (36) Steering gear box (37) Clutch pedal (38) Clutch housing (39) Starter motor
(40) Kingpin
(41
Front wheel (42) Front tire (43) A.C. Generator (44) Headlight (45) Front axle center-pin
Model
YM135D
(1) Muffler (2) Brake pedal (3) Step
(4) Differential lock pedal
(5)
Instrument panel
(6) Drag rod
(7)
Nukle arm
(8) Bumper
(9)
Battew (10) Ragiator, (1 1 ) Hood (12) Engine (13) Air cleaner (14) Fuel tank (15) Throttle lever (16) Steering wheel (17) Gear shift lever (18) P.T.O. shift lever
(19) Hydraulic control lever (20) Assist bar
)
Operator's seat
(21
(22) Fender
(23) Lift link
(24) Top link
A
Model
YM155D
(25) Top link hinge
(26) P.T.O. shaft (27) Lower link (281 Lift arm (291 Rear tire (30) Rear wheel (31
1
Brake (32) Transmission case (331 Brake rod
(34) Front wheel drive lever (35) Pitman arm (36) Range shaft lever (37) Steering gear box (38) Clutch pedal
(39)
Clutch housing (401 Starter motor (41 I Front wheel
(42) Front tire
(43)
A.C.
Generator
(44)
Headlight
(45) Front axle center pin (461 Range shift lever (47) Front axle (48) Front differential (49) Front drive propeller
II.

SPECIFICATIONS

1.
SPECIFICATIONS
(1)
1
EN­GlNE
I
block
I
L
Fuel system
I
Item
Type of engine
Number of cylinders
Cylinder layout
i
Bore
stroke
Cylinder liner type
I
~vcle Combustion chamber type Valve system
Displacement
Comoression ratio
(
Maximum output Maximum torque
[ngine weight
/
Pistion I Compression rings rings Valve t~ming
Valve clearances Engine starting
Ignition
Pi
lnjection timing
Injection pump
1
Injection pump plunger diameter
Injection plunger stroke
Injection valve type
Injection valve diameter
lnjectlon pressure
Injection order
I
Fuel
Fuel tank capaciry Speed control method
/
Scraper rings
Intake
valves
Exhaust
valves
i
Intake valves
Exhaust valves
Open Closed Open Closed
type
.
I
Unit / YM735 I YM735D I YM155 I YM155D
2T73A Engine model
I
2.874 x 2.953 2.953
jn
I
I I
1
173mm x 75mml
I
1
cu. in.
hplrpm
"'
1
1
I
degree
/
degree
I
degree
/
degree
1
FL
lbs
~n.
in.
38.3 (627
13/2700
25.312400 28.912200
1
(3.5 krml2400)
1
242.3(llOkgI
I
I
/
/
1 1
I
.
In. ~n.
<
I
I
1
1
~n. psi
U.S.ga1. 2.5 (9.5
Diesel engine
2
Vertical in line
I
I
Wet type 4-stroke cvcle
Precombustion chamber
Overhead valves
cc)
I
23 : 1
1
!
3
1
20' before T.D.C.
50' after B.D.C. 50' before B.D.C. 20° after T.D.C.
0.0078
0.0078 (0.2mm) Electric starting
Compression ignition
24'f
Yanmar Bosch
0.2756 (7mml
0.2756 (7mml
Semi throttle
0.1958 (5mm)
2.276 (160 kglcm2
Diesel oil
All speed mechanical type
(0.2mm)
lo
before T.D.C.
1-2
1)
2TR13A Engine
x
2.953
(75mm x 75mml
40.4 (662 cc)
1512700
14.0 k~-m/2200)
253.3(115kg)
PFR
2K
type
1
4.0
(152)
1
I
A
SPECIFICATIONS
(2)
1
EN-
!61NE
I
Lubri-
cating
system
Cooling
system
Electrical
system
I I
CHAS-
SIS
Power train
Item Lubricating pump type Lubricatins system
.
Lubricating oil capacity
Cooling system Heat dissipation method Starter motor type Starter motor capacity
I
A.C. generator type Generator capacity Current limiter Battery voltage, Thermostart plug type (optionall Thermostan Clutch
Trans­mission
capaciw
capacity
Clutch type
Fac~ng (outside diam.
x
inside diam.
thickness
Facing area
Static
torsue capacitv
Transmission type
Transmission Travel [Forwardl speed* 1st
x
meeds
1
Unit IYM135 YM135D YM155 YM155D
Trochoid
Force feed lubrication
1
1
1
U.S.ga1
V-KW
V-W
V-AH
V-A
In.
sq. in.
ft.
Ibs
0.44 (2.0
Water-cooled
Radiator
S114-219 (Hitachi), D.C. compound motor
'12-1.2
(GP8108 (KOKUSAN) magneto revolving
12-8.5
RS2130 (KOKUSANI
12-35
SH100-02 (HITACHI) magnetic valve type
12-13
Mechanical dry single plate
x
4.92 x 0.33
7.09
(180mm x 125mm x 8.4mrn)
20.4 (132cm2
97.7 (13.5 kg-m)
Mechanical. constant selective mesh gears combination
6-speed for forward, 2-speed for reverse
I
1
MPH (kmlhl MPH (kmlh)
0.71 (1.14)
)
1
1)
0.67 (1.071
1
I
r'\
(*Difference in specificarion depending on serial number)
CHAS­SIS
I
Running
gear
/
Item Rear axle type Front
wheel align­ment
Steer- 1 Steering svstem Ball - screw Ing
system
Tires
Option- Front Tire size /20x8.00-10-4PR-
/
al
I
Toe-in
Camber
Caster
Trail
/
King-pin inclination
Gear ratio
Steering wheel diam.
Gear box oil capacity Front
wheels
tires I wheels
I I
Tire size
Tire pressure
Rims
I
Tire pressure
Rims 5JA-12
Unit
degree
degree
(
degree
U.S.ga1.
psi
/
lb/in2 124.2 11.7 kg/cm2)
YM135
in.
0'
in.
in.
0
(
7O
15.0
4.50-10­2PR-FSR
17.8 (1.25 kg/cm2
3.506 x / 4JA-12
lOGA
I
0.16-0.32
1
15.4
:
(380mm)
2PR-FSL
5-12-
YM135D
Semi-floating
2.5O
0.43 (1 1 mm)
6"
1
0.05 (0.2 1)
PD
YM155
(4-8mm)
3O
o0
0
1
7O
18.9 : 1
15.8 (400mm)
4.50-10­ZPR-FSR
17.8 (1.25
)
3.50 x 14JA-12
1
10GA
1
6-12-2PR-FD
/
1
17.1 11.20 kg/cm2)
YM755D
2.5"
0.43 (1 1 mm)
1
6O
5-12-
2PR-FSL
kg/cm2)
.
-
-
1
1
system
I I
wheels Tire pressure ( psi 125.6 (1.8 kg/cm2)
Rims
I
option-/ Rear I Tire size
al tires
-
Brakes
I
I
Type Hydraulic Type of hydraulic pump
Position of pump
/
Purno drive
1
Pump discharge capacity.
wheels PD
Tire pressure psi 11.4
Rims 7001 x 15DT 5%K-16
Type of main brakes Internal expansion mechanical brakes Parking brake type
Lining surface area
Lining (width x thick­ness x length)
Brake drum diameter Method of activation Main brakes by foot
i
sq. in. 16.1 (104 cm2)
1
4
I
1
~.S.gal.j 3.76 (14.2 1) at 2700 rpm
I
5Xk-16
127~8.50-15-~PR- 1 8-16-4PR-FD
(0.8 kg/cm2
Locking foot brake
~n. 0.98 x 0.16 x 4.09 (25 x 4 x 104mm)
in.
Parking brake bv hand
/
In front of engine governor chamber
1
1
4.3 (IlOmm)
Gear pump
Claw couolino
1
22.8 (1.6 kg/cm2)
1
5Zk-16
22.8 (1.6 kg/cm2)
I
-
-
I
I
/-.
SPEC1 FICATIONS
(4)
,--
With
3-point
(*Difference in specification depending on serial number)
hitch
99.2"
l2520rnml
SPECIFICATIONS
(5)
ance
Maximum grade
Braking distance
[DIFFERENCE IN SPEClFlCATlONSj
degree
ft.
6.2 (1.9m)
11.5 (3.5171)
35O
7.2 (2.2m)
6.9 (2.lm)
11.5
7.2 (2.2ml
35O
(3.5m)
.-
P.T.O.
speed, r.p.m.
,--.
2.
POWER
TRAIN
(1)
No.
of
sear
NOTE: 'New 'indicates those after No.
'Old' indicates those before No.
teeth
51
51
001.
000.
1

POWER TRAIN

Nore:
(I)
0
hold only
(2)
*
Shofi. nnd
geor
(2).
,
YM135(D)IYM155(D) POWER TRANSMISSION STRUCTURAL DRAWING
FRONT TIRE
ro
YMISZDIYM135D
are
combined
,--.
I
DIFFERENTIAL
LOCK
POWER TRAIN
n
DIFFERENTIAL PINION
DIFFERENTIAL SIDE GEAR
(3)
FRONT DRIVING SHAFT
FRONT AXLE CASE
YM135(D)/YM155(D) FRONT AXLE SECTIONAL VIEW
(Before Serial No. 51000)
-7
KNUCKLE ARM. (L)
BEVEL GEAR
DIFFERENTIAL
PINION SHAFT
DIFFERENTIAL HOUSING
LOWER FRONT GEAR CASE
BEVEL GEAR
FRONT AXLE SHAFT
FRONT GEAR CASE CAP
FRONT
WHEELTIRE
2
POWER TRAIN
(4)
Yhl135(D)/YrV:155(D) FRONT
FRONT DRIVING SHAFT
FRONT
AXLE
CASE
7
7
\
AXLE
SECTIONAL
IAfter Serial No. 51001)
FRONT AXLE
r
i
rKNUCKLE ARM
VIEW
(L)
(L)
FRONT
WHEEL
TIRE
J'
3. Yh1135(D)/YM155(D)
DIFFERENTIAL HOUSl
FINAL REDUCTION GEAR HOUSING ASS
FINAL
REDUCTI
PINION (Ll DIFFERENTIAL
BRAKE COVER
(
TRANSMISSION SECTIONAL VIEW
INION SHAFT
DIFFERENTIAL LOCK CLUTCH GEAR
DIFFERENTIAL, LOCK CAM COVER
FFERENTIAL LOCK CAM
#'
BRAKE COVER (Rl
FINAL REDUCTION
EAR AXLE SHAFT
FINAL REDUCTION GEAR REAR WHEEL HUB
REAR AXLE HOUSING
FRONT P.T.O. SLIDING GEAR
LOW-HI SLIDING GEAR FRONT DRIVING GEA REVERSE GEAR
COUNTER SHAFT
1STlREVERSE
MAIN CHANGE S
DRIVEN SHAFT
DRIVEN GEAR AL REDUCTION
DRIVEN GEAR
IL)
LOW-HI REDUCTION GEAR
FINAL REDUCTION GEAR
REAR AXLE HOUSING IRI
NSMlSSlON HOUSING
P.T.O. SHAFT
0.
.O. REDUCTION SHAFT
E-WAY CLUTCH 10)
REAR COVER
REDUCTION GEAR
GEAR HOUSING
P.T.O. DRIVING SHAFT
TRANSMISSION HOUSING
.O. REDUCTION GEAR
HEADLIGHT
WATER TEMP
LIGHT SWITCH
WATER TEMP ~NDICATOR LIGHT
TURN TURN
SIGNAL SIGNAL
WORK LIGHT LEFT RIGHT
(redl
OIL PRESSURE
Graan
BUTTON SWITCH
5.

FUEL SYSTEM

6.
ENGINE LUBRICATING SYSTEM
No.
2
cylinder, ontake and exhaust rocker arm
I
I
Timing gear
case
Trochoid
pump
No.
1
cylinder. intake and
exhaust rocker arm
Cylinder head
No. 2 cylinder main bearing
NO.
1
cylinder main bearing
No.
1
cylindercrank
No.
2
cylinder crank
Suction
tube
-17-
.
Drain
Oil Oil pan
plug
R
Cylinder block
7.

COOLING SYSTEM

r-
Radiator
cap
47
Radiator
8.
TRANSkllSSION LUBEIHYDRAULIC SYSTEM
(Hot
water)
14
Cylinder block
I
Cylinder
heaq
/
Hydraulic control lever
Hydraulic
outlet
prn-tlr-
Transmission case
L.-.J
urar
pump-
Hydraulic cylinder
Hydraulic stop valve
11
Oil strainer
Ill.
NOTES:
(1)
separation or assembly stand (as shown below) should be used. (Please order the stand separately if desired.)
(2)
will be made on the premise that this stand is being utilized.
(3)
assembly stand is as follows:
TRACTOR
Whenever heavy maintenance work such as
The separation and assembly explanations
A
detailed diagram of the separation and
SEPARATION
is
undertaken a special
IV.
Division

DISASSEMBLY SEQUENCE

I
Pan Name
7.
Instal­lation
stand
Installation
stand
/
1) Utilize the top link hinge
(12
x
assembly bolt
1
tach the installation stand
I
2)
Utilize the front axle bracket assembly bolt (12 x to attach the disassembly
(A).
stand
3) Raise the rear tires by turn­ing the adjusting bar of both
(A) and (B). Prior!to this
stands adjustment loosen the flange bolts of the rear tire rim.
4)
Be sure to adjust both
(A1 and (BI uniformly
stands to ensure that the tractor
remains level.
CAUTION:
the front stand the
front
contact with
When attaching
tires
theground.
451
(A]
be
amain in
sure
to at-
(B).
30)
1
1
I
2
I~im
/
Flange bolts
Loosen the two flange bolts
and remove the snap pin (10
I
x
78).
The rear tire can then
be removed.
3
-
4
Division
Trans­mission case
Gear
case
='Y
final
reduction
Part Name
Oil plug
Pin
(Differential
lock rod)
20
8
x
28
Illustration
CautionlRemarks
Loosen the oil plug
drain the oil.
t
Pull
out the cotter pin (2
and
remove the pin (8
I201
x
to
x
281.-
I
151
A
-
5
Pin
8
x
17.5
(Brake rod)
Pull out the cotter pin (2
and remove the pin (8
x
x
151
17.5).
1
7
Seat
Opera&ores seat bracket
lllunration
CautionIRernarks
Remove the four nuts from
the bolts nuts from the bolts and remove the fender.
The operator's seat can be removed
two bolts three bolts
(10
x
651,
the two
(8
x 20).
by removinq the
I12
x
25)
x
and the
201.
(10
I
8
Trans-
mission
case Gear
final
High-pressure pipe
I
Loosen the adapter, and re­move the high pressure pipe
from the hvdraulic cvlinder
I
-
9
Division
Tranr mission case
Gear case
ass'y final reduction
Part Name
Low-pressure
pipe
Electric wire harness
Illustration CautionIRemarks
Remove the three bolts
181
and dismantle low pres-
sure pipe
Be sure oil filter when dismantl­ing.
I
Pull out the
the clutch housing.
(B).
not
to damage
wire
behind
(6
the
x
Dismantling transmission case from clutch housing
[Procedure
Remove the seven nuts
(12).
-
n
v
72
-
13
Division
Trans­mission
case Gear
case ass'y final reduction
Part
Name
Filter
Dismantling the transmission case from the clutch housing
[Procedure
23
1
Illustration
..
CautionIRemarks
Follow the same proceduri
as
in Step
Place a container for oil,
and remove the oil filter.
Separate the transmission case from the clutch housing.
CAUTION:
juster in Step
mansmission case and the clurch housing are level.
9.
Adjusr rhe
I
so
the
ad-
-
14
A
Separation
of transmis­sion case from final
reduction gear case
Remove the ten nuts separate the transmission case from the final reduction gear
case.
CA
VnON:
I)
When preforming this'
if
procedure,
and right side) at the arrow mark are hard to remove due to rhe exnuded porrion, gradually remove and remove the
2)
Arrach these nurs firsr during
assembly.
the nuts (on rhe left
rhe
transmission case
nurs.
(10)
and
-
16
15
Division
Housing hydrau­lic
cyl-
inder
Part Name
Lii
arm
(L)
(R)
Hydraulic cylinder housing
Illustration
Lilt
an
rr
CautionIRemarks
11 Lift arm
Remove the lift arm set bolt,
and force off the 21 Lift arm (R)
a) Remove lift arm set bolt.
b)
(8 x 201, and dismantle the
auto-return rod support.
CI
Remove the ten bolts and separate the hydraulic cylinder housing from the
final reduction gear case.
(L)
lift
arm (L).
Remove the two bolts
Lift off the lift arm (Ri.
(10
x
35).
L
77
Brake
I
Brake
ILI
(R)
.ip
.~
.-
IS0
.
..
Rsmove the nuts 18) (on the
&
right side), and remove
left the brake
.
-
(L).(Rl.
Dlvision
Part
Name
Illustration
Caution/Remarks
78
79
Brake
Gear case ass'y, final reduc­tion
Brake drum
Rear axle housing (L1
(R1
-
,
. -*<c*:.*:
;..
:-*
.-
1) Remove the bolt (8 x lock plate, washer, and lock plate.
2)
Drive the bolt into the
brake drum to remove
NOT&-:
M8
over
2)
and the (12 x 60) bolt. and the
two nuts
3)
loosen the flanged part and bolt pans. Remove with rhe
rear
For Step
bolr wit17 a thread length
1
in
(25
For example, i7ydraulic adapror cover firing
bolr
/M8
11 Loosen oil plug (101 and drain the oil.
Remove the 8 bolts (10 x 60).
Use a plastic hammer to
axle shaft as the base.
x
(121.
2)
mm).
451
use
16)
it.
an
.
.
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