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

troubleshooting procedures to be employ-

/p,&s-

Drive

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

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

/

1 1

I

.

In. ~n.

<

I

1

~n. psi

U.S.ga1. 2.5 (9.5

Diesel engine

2

Vertical in line

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

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

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

U.S.ga1.

psi

/

lb/in2 124.2 11.7 kg/cm2)

YM135

in.

0'

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

system

I I

wheels Tire pressure ( psi 125.6 (1.8 kg/cm2)

Rims

I

option-/ Rear I Tire size

al tires

-

Brakes

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

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

/-.

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

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

\

AXLE

SECTIONAL

IAfter Serial No. 51001)

FRONT AXLE

r

i

rKNUCKLE ARM

VIEW

(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

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

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

(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

8

x

17.5

(Brake rod)

Pull out the cotter pin (2

and remove the pin (8

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

.

Yanmar YM155d, YM135d Service Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

CONTENTS

NOMENCLATURE

SPECIFICATIONS

POWER TRAIN

FUEL SYSTEM

COOLING SYSTEM

DISASSEMBLY SEQUENCE