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

.

-

ivision

ood, lenric

arts

ngine

Irn

-

~

~~

Part Name

Iood ass'y lain wire

harness

lour meter

cable YM155D. 'M755 only1

lecornpres-

on lever

Illustration

Battery

plus

4

'L

.%

cord

-

Banery

ground

cord

2

WION:

J

Before remo~,ing the main

>ire harness, first dismantle

barrev plus

he

barrev grouild cord.

he

'I

Wl~eiz remorin: the main ?ire harness, it is recommeizdd for ease of handlinc not to emove the coni~ecrion in he instrument

72

2:>

Main

(+I

panel.

wire

cord and

hainerr

-

F.

0.

filter

----

:~el cock

Hour

merer

cable

-.

.--

--=

b>

Decornpresrion

lull out the bolt

nd remsve the fuel cock.

-:.-.

-+>

lever'\-,

(MB

x.70).

-

~

I..

I

Division Pan Name Illustration CautiontRemarks

I

High-pressure pipe

Remove the 3 bolts and take out the low-pressure pipe

(A).

Remove the 4 bolts and take out the highpretsure pipe.

(6

x

45)

124

1

r;.

l~uel oil tank

4

nuts

(8)

Loosen the remove the fuel oil tank

band. and dismantle the

1

fuel

oil

tank.

1

NOTE:

I]

Remove rhe cock ass) wirh the fuel oil rank connected.

2)

Phoro shows the procedure

for rhe

is different from

YMI3j(D],

procedure remains the same.

YMIjj(D),

bur rhe disassemblin~

to

rhe fuel rank

thar of rhe

I

-

25

-

26

Division

instrument panel

Steering

illustration

CautionIRernarks

Remove the instrument pinel

in the following sequence:

1) Steering wheel cap

!

2) Lock nut (14 x 1.5)

3)

Steering wheel

4)

Fuse

box,

5) Current limter, 4 screws (6 x 16)

6) Remove the instrument panel without removing the

main wire harness.

When removing the drag-rod,

use two plastic hammers

and strike the

fromboth sides.

end

2 screws (5 x 10)

pitman arm

27

Front

drive

Remove the propeller shaft

in the following order:

1)

Loosen the hose band and shift the setting rubber backward.

2) Remove the 4 bolts (6 x 10). and remove the propeller shaft cover.

3)

Take out the 4 bolts (6 x 16) to shift the propeller shaft cover supporter

4)

remove the propeller shaft.

(A)

Remove the 4 bolts

backward.

(8

x

20) to

1)

Jack up the front axle

bracket top and raise

the

front tires from the ground. 21 Remove the 4 bolts

and

remove the front tires.

(1

.41 Take out the castle nut

and extract the center

5)

Remove the front axle.

NOTE:

procedure for

YMI35D,

Photo shows the

YMI55D

but the same dis-

pin.

and

assembling procedure is used for the

YM155

and

2

x 2

(16)

V.

ENGINE DISASSEMBLY

Complete disassembly of the engine should be carried out in the following sequence:

Item

1

Radiator

and

air

cleaner

Illurnation

21 Detach radiator 31 Detach radiator with

assemblv.

Explanation

coolant from radiator and cylinder

hose.

fronr

axle

as

an

'.

\

11

Drain

Cylinder

2

i

I

!

head

4

21 Remove 31 Detach 41 Remove air cleaner 51 Detach

61

71

81 forget the nut in

91 Remove cylinder head gasket.

lube oil.

fan

generarar

fuel

Detach

rocker

Remove push

Remove

cylinder head nuts. (Do not

belt.

and

starter motor.

and

rocker

and lube oil piper.

arm assembly.

rods.

the intake rkanifold.1

arm

cover.

-

..

.

2)

Remove

crankshaft

crank

gear

by

the

drives.

31

Nore: me hydraulic

Do

Detsh

gem unir gear case but me removed as

When otsembling, remove rhe

hydraulic pump

gem unir to make firring

not

gear

using

use

a

c&.

ere

nor derachedfrom rhe

pulley.

two dot

gear

puller.

pump

nnd rnchomerer

md

rnchomerer

Remove

screw-

o

unir.

easier.

21

Check the thicknerr

31

Remove

the

lube

and

oil

dipstick.

number

of

the

21

Remove

under

31

Derach

lube

ail inlet tube.

41

Remove

rad

Caution: Cleorly

1)

Remove

which is No.

ir

No. 2 pisfon

the bolrr

cover

of

bolts.

mark

fo? later reference

1

pisron

(5pcrI.

cylinder block.

and

which

2)

Remove

using a gear puller.

31

Remove

hydraulic

lube oil

pump

pump.

driven

gear.

Item

lllunration

Explanation

8

Crankshaft

,'--

I

11

Remove

21

Remove

Caution:

main

beariog

crankshaft

Be

curem

bem'ng

not

housiog.

to

drop

the thrust

-

1

,'

.

11

Remove

Camshaft

9

21

31

weights.

Remove Remove

stopper.

camshaft.

tappets.

Remove

the

bearing

VI. ENGINE CONSTRUCTION AND MAINTENANCE,

1.

CYLINDER LINERS The

Cylinder liners must provide a good fit with pistons and piston rings, provide good heat dissipation, and must also have ample wear resistance

2TR13A, 2T73A

engine employs wet type

cylinder liners made of special cast iron.

(1)

Visual Inspection

The cylinder liner should be replaced when there

rust,

are visible scratches, traces of

(2)

Inspecting

by

Testing Equipment

or corrosion.

-

1.

2.

3.

cylinder liner

I

Roundness

Projection cylinder liner

Item

Inner diameter of

YM135(D)

YM155(DI

of

Standard dimension

2.8740-2.8752 (73+0.030

0)

29527-2.9539 (75+0.030,

0

Within

0.0008 (0.021

0.0019-0.0051

10.05-0.131

Replacement limit

0.0066 (0.171

(0.17)

0.0066

0.0039 (0.1)

-

T&ng equipment

Cylinder gauge

Dial gauge

[Unit: in

lrnmll

n

NOTES:

Measure the inner diameter of the cylinder liner in the

(I)

shaft

and in the direction of the piston at the following phces: a) at the upper part of

the liner

and c)

(2)

mined by

(3)

inder liner and also to provide

[l.I811.in (30

mm) below the rop of the linerj, b)

at the lower pan of the liner.

Whether the roundness of the cylinder liner

is

within the allowable

studying the differences in readings obtained in Item

The cylinder liner projection is necessaty in order to reduce distortion

a

good

fit

with the gasket when the cylinder head is

tightened. Accordingly, check to see that the required projection

axial

direction of the crank-

at

the center of the liner,

limits

1.

is

provided.

is deter-

of

the cyl-

(3)

Replacing Cylinder Liners C) Replace the liner rubber packings with a

new one.

Cylinder liners visual inspection and inspection by testing

-

ment

are replaced in the following procedure:

-

judged to be unacceptable by

equip-

d) Coat the liner with water-proofing paint.

Remove the cylinder liner and insert a

e) new liner.

After

it

f)

has been inserted, inspect the procedures previously described to ascertain that there is no contraction of the liner.

2.

PISTONS

it

using

Cyl.

A

Extmct the cylinder liner with

a) liner replacer.

Clean the grooves provided for the rubber

b) packing of the liner.

Item

1.

Outer piston

YM135lDl

YM155(01

liner

replacer

diameter

of

a

cy1inde.r

Standard dimension

2.8697-2.8709 173-0.078

-0.109

I

2.9484-29496

-OD78

(75-o.io91

The oval type pistons are made from terial sipation properties.

(1)

Check the pistons for scoring or cracks. Also check the piston ring grooves for chips or any wear in their edges.

(2)

Replacement limit

-0.0078 (-0.21

LOW-X

ma-

(Aluminum alloy) which has good heat dis-

Visual inspection

Inspecting by Testing Equipment

[Unit:

in

(rnrnll

Testing equipment

Micromerer

2

Clearance

h

pinon

between

and cylinder

0.0063-0.0068

10.1MI-0.173)

0.01 18

(0.31

r

3.

Item

Piston

ring

clearance:-

grooves

Standard dimension

Replacement limit

Testing

equipment

Thickness gauge(

(3)

Replacing Pistons

No.

1

2

3

4

0.0019-0.0033 (0.050-0.0851

0.0008-0.0022 (0.020-0.0551

0.0078 (0.2)

0.0079

10.2)

0.0079 (0.2)

0.0059 (0.151

NOTES:

Measure rhe outer diameter of the piston at the piston skirt section, at right angles

(I)

lrris of the piston pin

to the

Mensure the clearance between the piston and the cylinder liner by comparing the

(2)

outer diameter is the difference between the minimum clearance figure obtained of the piston.

of

the piston and the inner diameter of the cylinder liner. The clearance

and

the outerdimneter

(3.1) Disassembly

Detach the two piston pin retaining rings;

a)

Heat up the piston to 176" - 212°F (80"

b)

-

100°C):

Remove the piston pin by tapping

C)

it

with

a lead bar and a hammer.

(3.2) Assembly

e

Fit in one of the piston pin retaining rings;

a)

Heat up the piston to

.b)

-

100°C); No.2 & 3 Taper face type:

176"

-

212°F (80"

C) Fit the piston pin in position;

Fit in the remaining piston pin retaining

d) ring.

After assembly check to make sure that the piston and connecting rod move freely.

3.

PISTON RINGS

The piston rings have

Teflon@ coatings in order

to achieve good break-in properties.

The piston rings are as follows:

No.1 ring Barrel face type:

Provides and maintains good sealing properties and carbon crush-

ing properties; also prevents carbon sticking. Is chrome plated to achieve good wear-resisting properties.

Provides and maintains good sealing properties and oil scraping

effects.

No.4 Bevel cutter type:

An oil ring, in which the empha-

sis is upon oil scraping effects, is

used.

(1

)

Visual l nspection

Check rings for uneven wear or abnormal wear.

(2)

lnspecting by Testing Equipment

1.

Item

Piston ring grooves

and

clearance

Standard dimension Replacement

ring

[Refer

to section on pistons]

livit

1

Testing equipment

lll&tion

!

[Unir: in immll

7

2

Piston ring clearance:-

No. NO. NO.

NO.

2

3

4

1

end

0.0078-0.0157 (0.2-0.4)

NOTES:

To measure rhe pisron ring end clenrance, rhe cylinder liner

(I)

table, rhe ring is fitred in rhe skirr section, and after mnking sure that rhe ring is nor

rhe end clenrnnce is mensured with a rhickness gauge.

askew,

When rhe pisron rings are being firred in rhe pisron, be sure rhat the marking on

(2)

the ring is facing up.

4.

PISTON PIN

(1)

Visual Inspection

Check to

make

sure that there are no traces of

scoring, or uneven wear.

(2)

lnspecting by Testing Equipment

0.0591

11.5)

Thickness gauge

is

placed on a nufnce

I,

Item [Sandatddime~ion( Replacement limit I Testing equipment

[Unit: in imm)]

(

IllMration

1

5.

CONNECTING

RODS

(1)

Visual Inspection

The

connecting

big end sides have square cuts. The small bushings are made of sintered copper and lead alloy, and the large end side has kelrnet bearings.

rods

are

sramp

forged, and the

end

The bushings are checked to see whether there any scoring or peeling.

(2)

Inspecting by Testing Equipment

is

Item

Standarddimemion

Replacement limif

Testing equipment

Illurnation

6.

('Refer

Connecting

ilde

play

to

Note below)

rod

0.0Q59-0.0138

10.15-0.35)

Thickness

gauge

NOTES:

To replace the small end bushings, press-fir in new bushings.

(1)

operation be sure

sure the inner diameters afrer rhe new bushings have been diamerer is roo small, bushings

into position, be sure to align rhe oil passages of the bushings with those of rhe

rhar there is no peeling or contraction of the bushings.

press-fitred in position If the

it

should be corrected, using a reamer. When press-firrng new

connecting rod.

The clearance referred to in Irem 3 above is rhe difference befween rhe outer

(2)

diameter of

the piston pin and rhe inner diameter of the bushings obtained by measure-

ments.

During rhe

Mea-

The measurements referred ro in Irem 4 above are to be raken afrer righren-

(3)

ing rhe connecringrod bolrs to a rorque of 33 - 36 ft-lb (4.5 - 5.0 kg-m).

(4);

The clearance referred to in Irem 5 above is rhe difference benveen rhe inner

diameter of rhe big end bearing and the outer diameter measurements conducted using an oil

the case of Item 4, rhe measuremenrs are to be raken after the bolrs have been

As in

tightened

(5 afrer

to the prescribed rorque

The measuremenn refwed ro in Item 6 are ro be taken using a thickness gauge,

psr securing the connecting rods ro rhe crankshafrs and tighrening rhe bolts to

clemce gauge and/or a cylinder gouge.

0.f

rhe prescribed rorque and rhen moving the connectingrod ro one side

Ar least 75% of rhe roral area of the crankshafr bushings musr be in contact wirh

(6)

irselx

balance weights.

6.

CRANKSHAFT

the crankshaft

Extra overlap

The crankshaft used in the engine

a solid

two-

and pin sections, for increased durability of the

is

throw type, stamp forged and equipped with crankshaft.

the crankshafr obtained by

is

provided at the journal sections

n

(1)

Visual inspection

Check the crankshaft visually

of

there are any traces

(2)

Inspecting

by

scoring, marring,

Testing Equipment

to

see whether

or

cracks.

Tming

equipment

Micrometer

.

Unit: in

.

lllustGtion

.

.lrnm)

Dial

gauge

Cylinder

gauge

1

I

-.<

,

NOTES:

After conducting the measurements given in Irem I above, be sure to mensure the

(I) clearance

tion on measurements on the connecting rods for

(2) crankshnfr

the machining

supporting

between the crank pin bearings and the crank pin. (Refer to Item 5 in the sec-

the prescribed dimensions).

If, after measuring the crankshaft for deflection, it is found that machining of the

is

necessmy, do not forget to adjust the filler sections of the crank pins a.fter

is

completed. Measure the deflection by placing the crankshafi on a

stand

(3)

Irem 5

will

be the difference between Item 2 and Item 4 obtained through mea-

surements

Measuring of end play is conducted after the crankshaft has been fined into posi-

(4)

tion as prescribed

The roundness of the main bushings is checked by measuring the inner diameter

(5)

two directions at right a@es to each other and comparing the two readings obtained.

in

(3)

Replacing theMain Bushing

7.

CAMSHAFT

Whenever the readings for the main bushings exceed the repairable limit, they must be replaced.

When fitting the main bushings in the main bushings housing and cylinder block,

observe the fol-

lowing points:

a) To extract and insert bushings, always use the bushings removing and installing tools.

When inserting new bushings, be sure that

b) the oil passages are aligned.

After the new bushings have been install-

C)

ed, measure the inner diameter of the main

bushingto check that they are properly aligned,

not contracted.

and

A

single, integrated camshaft, incorporating the in-

is

take and exhaust cams, and the fuel cam,

used.

The fuel cam has straight flank and convex curves while the intake and exhaust cams have parabolic acceleration curves, in order to reduce the shock of inertia force, this also serves to effectively

re

duce noise.

(1)

Visual Inspection

Check the crankshaft for marring or uneven wear.

Be sure that the supporting function correctly,

and that no abnormal noises are generated.

(2)

Inspecting

by

Testing Equipment

Unit:

in

imhl

A

for

distortion

1.6505--1.6515

outer

diameter

camshaft bearing

and cylinder block:

of

Unit:

in

(rn

NOTES:

To conduct the measurements referred to in Irem I above, the camshaft

(1)

is

secured

to a supporting stand, and the amount of run-out is measured using a dialgauge.

The cam journal clearance referred to in Irem 3 is the difference in the read-

(2)

ings obtained by measuremenrs of the two components taken using a micrometer

and a cylinder.

Valve timing and fuel injection timing is shown below

(3)

T.D.C.

7

B.D.C.

The clearance between the rappers

(4)

is

the difference benveen the readings for the components taken using a micro-

and

tappet guides referred to in Item 6 above

meter and a cylinder gauge.

Replacement of the camshaft ball bearing

(5)

is

conducted by first removing the old

bearing by a puller and press-fitting the new ones in position

8.

CYLINDER HEAD

A

cylinder head integrating two cylinders into

one and made by high precision quality casting

is

used.

Both the intake ports and the exhaust ports are

integrated in the cylinder head, and overall engine design and construction has been simplified by eliminating manifolds.

Item

1

Inner diameter valve guider (after assembly)

2.

Outer

diameter

of valve Remr

standsrd

Intake:

of

0.2755-0.2761 (7+0.015)

Exhaust:

0.2763-0.2775

!

(7+0.020

0.2736-0.2740

1

17-o.040

dimemion

+O

+0.050)

-0.050)

Replacement limit

0.0031 (0.08)

-0.0039 (-0.1)

(1)

Visual Inspection

The

surface

are any traces of coolant

of the head

is

checked

or

gas

to

leakage. ~h~

side of the head is checked to ascertain that

not clogged up anywhere by accumulated debris

is

and that there

(2)

Inspecting

Testing equipment

Wire gauge

Micrometer

[Check thor rhe reading wrhm the standard

no corrosion.

by

Testing Equipment

lllunmion

is

dimension]

see

Unit:

if

there

in

in.

it

(mm)

is

1

3. Wearance valve guide and valve stem

4.

5.'

6.

seat width:

Valve

Intake Exhaust

Amount of sinkage

Valve springs:

Inclination Free length

beween

valve

Intake:

0.~15-0.0025 (0.040-0.0651

Exhaust: 0,001 7-0.0027 (0.045--0.070)

0.0696 (1.771

-

1.4370 136.5)

0.0059 10.151

0.0984 (2.5)

0.0197 (0.51

2 degrees

1.6142

(41)

b-

Caiipen

lCalipen

Calipers

7.

Valve reat angle.

!

intakelexhaurt

90 degrees

NOTES:

Measure the inner diameter of the valve guides after they have been fitted

(I)

into position A press must be used to

press-fir the valveguides into position when they

are replaced

is

If there should be increased

Before the intake

insufficient clearance between the valve guides and the valve stems, clearance

to rhe prescribed dimension by usinga reamer.

&

exhrmst valves are installed, coat the valve stems with lub oil.

The width of the valve sears

(2)

is

measured by a pair ofcalipers, and

if

corrections are

necessq, the prescribed valve curter must be used.

Ouzer diameter Inzoke

(3233.1) 1.0590-1.0669

Exhausr

of

volve:

(2 7iU.1) 1.2559-1.263

7

After the valve seats have been dressed using the seat cutters, the valves are lapped.

i) Lapping should be done by using valve lapping compound powder.

ii) The finishing of the seat should be done by oil lapping.

iii) When fitting the valves back in position, do nor mix up

inder with those of the No.

2

cylinder. All valves are marked prior to shipment

the valves for No. I cyl-

from the factow whether they are intake or exhaust valves,' and also whether

they are for the No.

1

or No. 2 cylinders.

ICI

IB)

15'

(CI

65-75Ocl;trer

cuner

Seat

width

0.0696

mml

Valve

seat

cuner

9.

COMBUSTION CHAMBERS

n

The combustion chambers consist of Yanmar's patented special swirl type pre-combustion

cham-

(1.77

(1)

Visual Inspection

Check the combustion chambers to see that the

bers. They improve combution performance and injection ports are not clogged or that carbon de-

contribute to achieving low fuel consumption. posits have not formed.

in.

(2)

Points to Bear in Mind in Assembling the a) Chamber packing Combustion Chambers

When assembling the combustion chamber, carry out the work in the following sequence. Note that the front chamber has front and rear sides.

b) Front chamber C) Chamber packing

d)

Rear chamber

e) Teflon@ gasket

10. ROCKER ARM ASSEMBLY Independent rocker arm supports are provided

for each of the cylinders. Lubrication of the

is

rocker arm

-

lube oil fed under pressure from the lube oil

carried out by forced lubrication

pump.

1.:

2..

-

Outer

of

rocker

i

shaft

Inner

of

rocker

bushing

Item

diameter

arm

diameter

arm

Standard

0.5504--0.5511 ,14-0.018

0.5518-0.5525 '14~.026'

dimension

0)

iQ.034

Replacement

-0.0039 (-0.11

0.0039 10.1)

limit

(1) Visual Inspection

Check the rocker arm support, the shaft, and the rocker arm bushings for cracks.

(2)

Inspecting by Testing Equipment

Teting

equipment

Micrometer

Cylinder

gauge

Illustration

.. .

Unit:

in

(mml

3.

4.

t

Clearance

rocker

and

of

bushings

Length

rods

arm

inner

rocker

beween

shaft

diameter

arm

of

push

NOTES:

(I)

placed rhey should again be press-firred. After they have been fitted, measure them

to be sure rhey me nor

(2)

(3)

11.

n

INJECTION PUMP AND INJECTION

VALVE

An

integrated.fuel pump, a Bosch

manufactured by Yanmar,

0.OW6-0.0020

(0.016-0.052)

6.5157 (165.51

The rockers

0.0059 (0.15)

-0.0787 (-2)

am

bushings are press-fitted in position and when rhey are to be re-

noocked nor

Calipers

is

there imy coniracrion

Place the push rod on a surface table to check rhem for straghmess.

Align the oil-port when replacing bushings

and No. 2 cylinders.

The nozzles are of semi-throttle type, to achieve

PFR2K

is

used for the No.

type

1

lower combustion noise (low rpm knocking)

out impairing engine starting performance.

with-

(1)

Inspecting by Testing Equipment

lOOOst

(at

rpml

of

cam shaft

2T73A.

22ccl

lWkt

(at

1350

1250

(2)

Disassembly, Assembly, Adjusting

(2.1)

Fuel Injection Valves

The injection valves are built as shown in

a) the illustration below.

Valve

Adjusting shim

Valve

spring reminer

holder

body

spring shoe

Fuel

valve

injection

S'Y

b) Injection pressure

is

adjusted by vary:

ing the thickness of the adjusting shims. Every

0.0039 in. (0.1 imately

142- psi (10 kg/cm2) variation in/ the

mm) of shims provides approx-

pressure.

Be sure to use shims which have holes in their

centers.

[Adjusting Shim]

Injection condition

mm

C)

The injection pressure 2,276 psi (160 kg/ (2.2) Fuel Injection Pump

0.5

11 025053420 11025053430

cm2) is of course important, but be sure to check the fuel is injected correctly as shown below: inder.

-

DISASSEMBLY SEQUENCE

Measure the injection volume of each cyl-

a)

Measure the pressure to be generated.

b)

(more than 7,112.5

Whenever any of the plungers have to be

c)

psi1500 kg/cm2

)

replaced because of wear, the disassembly and assembly work is carried out in the following sequence.

Plunger diameter and cam

lift:

0.2756 in x 0.2756 in (7oi x 7 mm)

-

[NO.

1

CYLINDER]

J.

Plunger guide roller pin

2.

Plunger guide roller Delivery valve

3.

Plunger guide Plunger

4.

Plunger position adjusting shim

5.

Plunger and plunger spring retainer

6.

Plunger spring

7.

Plunger spring retainer

8.

Fuel control pinion

9.

Delivery valve holder

(A)

Fuel control pinion (A)

Plunger spring retainer Iuqperl

Plungw spring retainer (lower

Plunger position adjusting shim

.Delivery

barrel

valve

packing

spring

sea

Delivery valve holder

uel injection pump

ars'y

O-ring, for delivery valve holder

10.

11. Delivery valve spring

12. Delivery valve Delivery valve seat (including packing)

13.

A~T

venting

boll

14. Plunger barrel

15. Plunger barrel packing

[NO. 2 CYLINDER]

16. Fuel control pinion screw (Check scribed line)

17. Plunger guide roller pin

18. Same procedure as

19. Sleeve

20. Same procedure as

21. Fuel control pinion (8)

22.

Rack.

(3

to

7).

(8 to 151

Fud control pinion

Plunger

guide

mllcr

Runger

uel control

Rungr

guide

nck

guide

dler

roller (inner)

(outer)

-

When disassembling the fuel injection pump, do

not

mix-up the parts for the No. 1 cylinder and

2

No.

on different trays.

cylinder. Keep the pam for each~cylinder

[Points to Bear in Mind in Assembly]

Do not mix up components for the No.

(1)

2

cylinder and No.

cylinder.

-

1

During assembly, clean each component be

(2)

fore fitting into position.

(3)

After assembly, make sure that the rack

moves freely without resistance.

Be sure to align all assembly markings and

(4)

scribed lines.

ASSEMBLY

[NO.

1

CYLINDER1

1.

Plunger barrel packing

2.

Plunger barrel

Delivery valve seat and packing

3.

4. Delivery valve

5. Delivery valve holder O-ring. (Torque: 30-32.6

6.

~eliv'ery valve holder

Rack (Make sure that the rack

7.

Fuel control pinion (A). (Line up alignment marks.)

8.

Plunger spring retainer. (Check which side should be

9.

10. Plunger spring Plunger (Line up alignment marks)

11.

12.

Plunger spring lower retainer Plunger position adjusting shim. (Adjust the plunger

13. to close the port of barrel by the

pre-fit volume

is

0.098" (2.5 mm).)

is

fined in the correct direction.)

shim(s) in which

SEQUENCE

ft.lbs/4-4.'5 kg-m)

up.)

14. Plunger guide

15. Plunger guide roller

[NO. 2 CYLINDERJ

Fuel control pinion

16.

17. Plunger barrel Same procedure

18.

19. Fuel control sleeve. (Line up scribed lines on control pinion IB) and sleeve.)

20. Same procedure as 9 to 15.

21. Rocker pin

(B). (Line up alignment marks on rack and control pinion.)

as

13 to 6.

ntrol

-

After assembling the fuel injection pump, measure the rack motion resistance. Motion resistance should be less than

by

a

spring scale,'?r when rack is placed in the

vertical position

its

full distance of travel freely by

12.

GOVERNOR

The speed control system consists of a mechan-

ical, centrifugal weight, all-speed governor. The governor weights are fitted to draulic oil pump drive device. By a sleeve at the end of the hydraulic oil pump motion

Item

0.132

it

should be capable of moving

Standarddime~ion

lbs

(60

g), measured

its

own weight.

a

gear on the hy-

Replacement limit

travel through the governor lever and move the rack of the fuel pump. In addition, this engine is equipped with a increase the amount of fuel supplied as neces-

sary.

13.

LUBRICATING OIL PUMP

(1)

Pump

A

pump.

[Inspecting

TeRing

trochoid pump

by

equipment

is

used for the lub;icating oil

Testing Equipmentj

rt'orque spring to

lllunration

!inkage to

i

Unir:

in

lmml

~..

Clearance between outer

r01or and

body

Clearance

body and ouxer rotors

Claarance between outer rotor and

inner

rotor

between

inner.

0.0020-0.0041

10.050-0.105)

0.0024-0.0039

10.1 0-0.061

0.0020--0.0041

10.050-0.105)

0.0059 (0.15)

0.0051 10.13)

10.1 51

0.0059

Thickness

Square gauge Thickness

Thickness

gauge

i

!

I

,

.

i

*.

.

&-

'..

,.

.c

,

.

:

..

a.

A

1

i

!

i

L

-53-

(2) Lube Oil Pressure Oil pressure control valve:

21.34--35.56 psi (1.5-2.5 kg/cm2)

Oil filter by-pass pressurevalve activating pressure:

17.07-1 1.38 psi

Lube oil pressure control valve

(120.2 kg/crn2

is

fitted on lube

)

oil filter.

14. COOLING SYSTEM

(1) Radiator

Backlash

Item

The radiator cm2

).

Apply pressure to the cooling system to

test whether there are any leaks in the

is

pressurized at 12.8 psi

(0.9

kg/

svstem.

15. GEARS

(1)

Measuring Backlash

Fit each of the gears in position, and measure

their respective backlash readings.

Unir:

in.

(mml

\

Standarddimension

0.0031-0.0063 (0.08-0.161

RePImment

0.01

18

(0.31

limit

Testing

equipment

Dial

gauge

Fuse

Mircomerer

IlluRration

a

(2) Visual Inspection Check the gear tooth faces for pitting and if any

gear shows severe pitting replace

(3)

Tachometer Gear Unit (only model 2TR13A

it.

engine)

Check to make sure that the gear unit functions smoothly.

16. OIL SEALS, O-RINGS AND BALL BEARINGS

(1) Oil Seals

o

Crankshaft - fined on both ends

-

Flywheel side Gear side

o

Decompression shaft

o

Regulator handle shaft

(3)

Bal! Bearings

o

Camshaft

o

Hydraulic pumpdriven gear shaft

-

main bearing housing

gear case

Chapter V covered maintenance and servicing of

various parts of the engine. During engine

assem-

bly the following points should be observed:

(1)

All packings should be replaced with new

ones.

All residues of the old packings should be completely removed.

(2)

All packings should be coated with appro

priate sealants.

Refer to the following charts for tightening

(3)

torque specifications. Note, however, that toque specifications for the more important bolts and nuts will be provided in the sections on their

as-

sembly.

A

Effective diam-

eter

of bolt M5

M6 M8 MlO ~12' M14 M16 M18 MZO

B

Width

aoorr

bolts and

0.3150 in. ( 8mm)

0.3937 in.

0.5118 in. 03 mml

0.6693 in. (17 mm)

0.7480 in. (19 mm)

0.8661 in. (22 mml

0.9449 in. (24 mm)

1.0630 in. (27 mml

1.1811 in. (30 mml

3)

Camshaft rtoper

Take care not to get front and

.of

thrun bearing mixed

nuts

flats of

HO

mml

'

screw

up:

C

4T (Mild steel)

2.2 - 2.9 ft.lbr . (0.3 - 0.4 kg-ml

3.6 - 5.1 ftlbr (0.5 - 0.7 kg-ml 9 - 12 ft.lbr (1.3 - 1.7 kg-ml

18 - 24 ftlbr (2.5 - 3.2 kg-ml 33 -43 ftlbs (4.5 -6.0 kg-ml 51 - 61 ft.lbs 17.0 - 8.5 kg-ml 80 - 1OOft.lbs (11 - 14 kpml

116- 137ft.lbr (16 - 19 kg-m) 159 - 195ft.lbr (22 - 27 kpml

rear

sides

D

7T

(Hard

Reel)'

5.8 -8.7 ft. 17- 22 ft.lbr (2.3 -3.0 kg-m)

33 -43 ft.lbr (4.5 -6.0 kg-ml

58 - 72 ft.lbr (8.0 - 10 kpm)

87 - 108fr.lba 12%- 152ft.lbr (17.- 21 kg-m) 174- 210ft.lbs (24 239 - 297 nlbr 133 - 41 kpm)

Ibr (0.8 - 1.2 kpm)

d2

-

15 kg-m)

-

29

kg-m)

Remark

I

2) Main bearing housing Ascertain that crankshaft

Crankshaft side gap

turns readily

Cylinder block

flywheel end below.

11 Pinon assemblies luring a pinon ring

is

stood

on

(No.

1

insertion

its end with

&

No.

2)

tool!

dl Mark on large-boss end

md

(Match

cap

is

aligned with

same mark1

2)

Align matching

markson

the

Hydraulic

pump

drive gear

Fuel

oil'pump:

0

Fit rack to notch and attach pump

0

Insert injection timing control shims

to prescribed thickness.

be

The following should

0

Lube oil pipe;

poirnr on the cylinder black

TWO

0

Lube oil pressure witch

0

Lube oil dipstick

2)

Coat

oil real with lubeoil, and push-fit

the crankshaft

damage lip section of oil real.

3)

Lube oil pressure control

lube oil filter.

4)

V-pulley: to crankshaft

5)

Hour meter gear unit

V-pulley. raking care not to

done before the

valve

and

6)

Hydraulic pump

Item

Description

Tishtening torque

ft-lhr

lkg-rnl

:

IlluRration

8.

Adjusting amount of fuel injection

9.

Cylinder head

11 Loosen the injection control to the point where governor lever will not come into contact with lever is moved all the way in the increase

direction,

21 bolt and move linkage all the way in the increase direction. i.e.. to the left, and

then tighten coupling bolt 31 Align mark on the rack with datum

level of pump by moving injection

control shaft 41 Lock injection control.

51

61 Anach fuel injection pump cover.

1) Fit gasket, taking carethat rhe correct side be visible).

21 31 Cylinder head 41 Rocker arm assembly

5)

[Looren the adjustment screw before

atiaching the rocker arm1

i.e., to the left).

Loosen

the governor linkage coupling

towards thegear care.

Attach rupplementlry oil inlet

is

up

(Side with strips should

Push

rods.

Lube oil pipe.

(locren

it

even when

.

114-116

(15.5-16.01

1_

-

10.

Item

Valve clearance

d-iption

1)

No. 1 cylinder (flywheel ridecylinderl

is set to the TDC where there ir comprer-

rion.

[The TDC where there

the point when the stamped mark of the crankrhaftlv-pulley is aligned with the Pointer of the gear intake

nor

exhaust valves move.)

2) The adjusting screw is loosened, clear-

ance is adjusted to 0.0078 in. 10.2 mm)

(for both intake and exhausti, and after

adjustment, tightened

3)

The valves for No. 2 cylinder are also adjusted to clearances of 0.0078 in (0.2 mml after turning the engine exactly 180 from the TDC there is comprerrion.

for

is

compression is

case,

and neither

once

again.

No. 1 cylinder where

Tightenirg torque

ft.lbr

kg-mi

lllunration

'Y

.

,-.

11.

Radiator

11

A.C. geneator

2) Cooling fan

[The fan belt should be rightened to the point where the fingers 0.4-0.6 in (10-15 mmi at point midway beween The generator

pulley and rhe 31 Radiator front axle bracket 41 Starter motor

5) Air cleaner

6) Exhausr muffler

it

may be pressed down

fan

shaft.]

by

a

VIII. ENGINE ADJUSTMENTS

This chapter will discuss those places which quire adjustment after the engine has been assem- vidual components, refer to Chapter

bled.

Governor Governor

weight

spring.

re

For detailed servicing and adjustments of indi-

1.

GOVERNOR LINKAGE

V.

Remove the fuel pump chamber cover.

(1)

Remove the cap nut and loosen the lock

(2)

nut.

Lightly move the governor lever as far to the

(3)

left as possible so that the fuel injection rack

touches the fuel injection limiting shaft.

Free the governor lever. At the same time

(4)

screw the fuel injection limiting shaft in.

Lock the fuel injection limiting shaft when

(5)

is

the end of the punched mark on the rack

up with the datum lever of the pump.

(6)

Attach the fuel pump chamber cover.

lined

limitingghaft

2.

VALVE CLEARANCE

No. 1

(1)

to the

(This is done the crankshaft pulley with the indication pointer on the gear case.)

(2) The valve clearance adjusting screws are

loosened.

(3) A thickness gauge 0.0078 in. (0.2 mm) serted and the adjusting screws are adjusted so

that both intake and exhaust valves have tha

amount of clearance, and then the adjustir.,

screws are locked.

cylinder (flywheel side cylinder)

TDC

position where there

by

lining up the stamped mark on

is

compression.

is

set

is

in-

sann

44) The flywheel from this position clockwise (that. is, the TDC

position at which there

other cylinder).

(5) The procedures described in (2) and (3) are

repeated for No. 2 cylinder to adjust the valve clearances to 0.0078 in. (0.2 mm).

is

now turned exactly 180"

is

compression in the

3.

FUEL

The timing of the injections from the fuel pump delivery valve is checked in the following order with fuel being fed to the fuel pump by oiler.

(1) The No. 1 cylinder tion where there

(2)

The flywheel

small increments.

(3)

The flywheel is stopped at the very moment

that fuel

(4) The angle between the stamped mark on the

crankshaft V-pulley and the indicating pointer on the gear case at the time fuel checked.

Correct fuel injection delivery timing is when

(5)

the stamped marking and the pointer are lined

up, which

INJECTION TIMING

a

is

set to the TDC posi-

is

compression.

is

moved back and forth in.

is

discharged from the delivery .valve.

is

discharged

is

24 degree before TDC.

hand

is

If the fuel injection timing

(6)

timing is adjusted by removing the

if

it

is

ahead, add the shim(s).

Every 0.0039 in. (0.1 mm) shim provides approx-

imately 1

I

degree of variation.

Overlap

is

lagging, the

shim(s), and

1

4.

FAN

BELT

Loosen the charging generator mounting bolt and.

the belt adjusting bolt, and adjust

tension so that there is 0.4

mm) of play at a point midway between the fan pulley and the generator pulley, and then tighten

each of the bolts.

TENSION

the fan belt

-

0.6 in. (10 to

15

(3)

Carry out the same procedure given in

with the air venting plug

14)

Loosen the in the same manner as described in lease any air.

Loosen the injection valve side of the fuel

(5)

injection pipes.

air

venting plug of the fuel pump

(B).

(2)

to re-

5.

AIR

VENTING

1

Put fuel into the fuel tank. Loosen the air venting plug

(2)

filter, allow fuel to flow from fuel flowing out tighten the air venting plug.

(Bleeding)

is

free of air bubbles, and then

(A)

of the fuel

!he plug until the

(6)

Put the shift levers in neutral, the throttle lever in running position, move the decompression lever, and then turn the engine with the motor.

(7)

As soon as fuel starts reaching the No. 1 and

No. 2 cylinders from the injection valve side,

ghten the fuel injection pipes for each cylinder.

(8)

Move the decompression lever once again

a

and turn the starter motor. If

is

which indicates injection

is

the venting

6.

OTHER MEASUREMENTS AND INSPECTIONS.

compteted.

taking place

spurting sound

.starter

is

heard,

ti-

Lube oil pressure: 21.34-35.56 psi

(1)

2.5

kglcm'

Attach a pressure gauge to the fitting of the lube

oil pressure switch and measure lube oil pressure.

'7

I

,

(2)

Top clearance: 0.030-0.022 in. (0.67+0.1

mm)

Extract the

a)

front), insert fuse rod through nozzle mount-

ing port, and turn flywheel.

Squash the fusebetween the cylinder head

b) and the piston crown.

Measure the thickness of the squashed

C)

fuse using a micrometer.

combution chamber (rear and

)

(1.5-

IX. ELECTRICAL EQUIPMENT

The Model YM155(D)/YM135(D) tractors are fitted with the following electrical systems:

(1) Starting system (2) Charging system (3) Lighting system

(4)

Safety system

1.

BATTERY

(1)

Specifications

-

Model

Capacity Voltage

Electrolyte

specific Charging current

Item

gravify

nglne

01

pressure

ater temperature

Specifications

Y60-S4LP - YM155.155D Y60-S4P - YM135.135D

35AH (20-hour rate1

12V

1.260/68~~ (20'~) at full

charge

3.5A

(2)

Battery Description

The open circuit voltage of a battery measured across its terminals is and neither the size of the battery nor its number

of plates has anything to do with its voltage.

The capacity of a battery is the amount of electricity that can be discharged from a fully battery at a constant flow until discharged terminal voltage.

There are two ways of expressing

2.0

-

2.15 volts per cell,

charg*

it

reaches its ra

the capacity

of a battery: by capacity (AH) or

ity

(WH). Generally speaking, the 'Ampere

Hour Capacity'

its

'Ampere Hour' electrical

its

'Watt Hour' electrical capac-

is

used.

sulfation will ensue, and

it

will no longer be

possible to recharge the battery.

Electrical capacity (AH)

=

discharge current

(A) x hours of dis-

charge

(H) required

for battery to reach

discharged terminal

voltage

The capacity of a battery will vary according to

its

discharge current rate, the ambient temperature during discharge, and the time and manner in which the battery

is

used.

The capacity will also vary according to the

temperature of the electrolyte during discharge. The higher the temperature, the larger the capac-

ity; and the lower the temperature, the lower the

capacity.

-

When starting the engine, the battery discharges at a very high current flow rate. Accordingly, can be readily understood that starting difficult when the ambient temperature is very low, because the capacity of the battery

ed. In addition, the viscosity of the engine oil also increases as the temperature drops.

is

lower-

it

more

Too

low

&rrm

b) Specific Gravity

level

OMrfilled

The specific gravity of the electrolyte of a bat-

(3)

Inspection of the Battery

a)

Electrolyte Capacity

tery varies according to the temperature.

The specific gravity should be adjusted to the

specific gravity at

68°F

120°C).

The water content of the electrolyte will evaporate during use, or will be reduced in

is

volume because of electrolysis. If there sufficient electrolyte, the

it

sustain damage, and

there

battery

is

too much, the electrolyte will overflow and damage the body and other parts of the tractor.

According1y;the level of the electrolyte in the

battery should be inspected regularly, and re-

plenished with distilled water when insuffi-

M

cient. The level of the electrolyte should be

sufficient so that the separators of the plates

,

in-

liable to

Specific

gravity

1.260

1.220

1.160

1.090

1.080'

1.050

100%

75 50 25

10

0

Condition

Charged

Usable

limit

Discharged

Fully

discharged

condition

Usable

ar

it.

Recharge

immediately.

are not exposed.

Use

If

the plates are exposed to the atmosphere,

a hydrometer to get the specific gravity

reading:

Insert the hydrometer into one of the battery

holes and

suckx~p enough electrolyte into the glass tube so that the float moves freely. Be sure to hold the glass tube vertically; the read-

is

ing at (A)

the specific gravity

11

Rotating

21

Operational rotation

3)

Allowable

4)

Charging

51

Rotation

charging

(2)

'Structure

direction

rotation perofrmance for

initial

Clockwise

1000 12,000

Moie

mm

than

rpm

1500

(viewed

-

5000

8.5A114

rpm

fmm

rpm

at

flywheel

4000

ridel

rpm

Name: 8-8 pole magneto revolving type genera-

tor

Components:

a) Stator (armature windings)

i) Each coil is connected in series. Wire

conductors are wound around an 8 pole

armature core.

A

2.

GENERATOR & CURRENT LIMITER

(1)

Specifications

Generator: Current limiter:

GP8108 (KOKUSAN)

RS

2130 (KOKUSAN)

An aluminum die cast plate has recti-

ii) fying diodes attached to

it.

b) Flywheel

The throttled plate flywheel has a ferrite mag-

net attached to

it,

and the pulley, shaft and

bearings are pressed in.

(3)

Connecting Diagram

Connecting Diagram (GP8108, RS21301

-

(4)

Description of Motions

Circuit Without the Current Limiter Operated and Too Much Charging Current Flowing

Whirel

Circuit With the Current Limiter Operated and Too Little Charging Current Flowing

AC electricity, generated by the generator, is rec-

/--

..

t~fled in a full wave to DC electricity [red cord:

positive

through four diodes.

than the battery voltage,

(+);

and black cord: negative

When

it

is charged into the

becomes higher

-

(-11

Current

ilmiter

7f

-

,

!

Swlxch

Banen, 12V35AH

Head

Starter

(load)

lamp

and

motor

%

of an AC

Red

-

I

battery. When the current being charged increases with the high speed applied,

waveform generated is cut to adjust the current

being charged by the action of resistors and zener

diodes in the current limiter.

3.

INSPECTION AND CHARACTERISTICS

(1)

Performance test of the generator coupling

with current limiter connected as shown on

D.

67.

Condition between

charge current

of

voltage terminal

battery

Normal

1) More than 7A at 14V lwirhout Current limiter1

21 7-2A at 14-15.W lwith

current limiter)

(2) Separate inspection of generator

(Refer to diagram on p. 72)

[On

Performance]

Approx. more than 28V. DC

Abnormal

11 Current: more than 7A

Voltage: more

21 No charging current

31 Charging current noted

but voltage of

terminal is

Approx. less than 28V.

than 15.5V

battery

Iw

Causes

Current limiter is not

operating properly. Current limiter and

generator are not Operating properly.

Battery

OC

11 Diode is bad 21 Open circuit in armature

between lead (red)

Dicde A-lead (red)

continuiw

No

3.

[Inruration resistance1

at:

500V

Mesa tester

Lead (red)-grounding

Normal

More than

3~fi

Abnormal

Less than 3Ma

Causer

Bad insulation at armature

coil

Rotating

Flywheel rotated

I

4.

A

I

1.

2.

3. DO not tighten belt too tight

4.

1

5.

6.

7.

8.

1

''

10.

Condition

of

the Flywheel

Normal

Magnetic rtresi felt 8 times Per

1

rotation. Rotates comparatively

Abnormal

1

Noire accompanies rotation

No magnetic

Light rotation flywheel

CAUTIONS DURING HANDLING AND ASSEMBLY

Cautions

DO not improperly wire Confirm

DO

Avoid shocks the flywheel

Do 00

(engine operation must always be under specified wind

speed condition by coaling fan)

Do not

During arrernbly and disassembly. the shaft tightening

torque:

Use

reolacement of bearina Ure genuine Yanmar parts for the replacement of

generamrdiodes

I+) & I-),

not operate at

and

not hang lead wire not operate out of the specified asrembly condition

pour

water into the generator unit

250

kgcm to

rated or genuine Yanmar part for the

to

banev.

and coloring of leads

less

than the specified speed

large stresses

300

on

kgcm.

the peripheral of

/

I

Resulting Problems

Short-circuit

1)

Burning of generator diode

2)

Burning of generator coil

3) Burnina of current limiter Burning of generator coil

Failure of current limiter

Broken pulley & bearing of generator Distortion of

Break

of

lead wire

Burning of current limiter & generator

Short-circuits

Damage to bearing Damager to flywheel by the loosening of

SCI~WI

Damages to bearings

Burning of diodes

stress is felt.

of

battery

the flywheel

of generator

Causer

/

Bearing is bad

Distortion of the flywheel Lowering. or failure of

magnetic energy of

i

'

I

/

I

1

5.

INSTRUCTIONS FOR DISASSEMBLY

AND ASSEMBLY

(Refer to diagram on p.

[Disassembly]

(1)

Remove hexagon nut (c);

(with attaching the top of the shaft ("side);

do not put stress on the flywheel)

(2)

Dismantle the flywheel (a);

(lightly tap the top of the shaft with

wooden hammer)

(3)

Separate the lead wire from each diode ter-

minal

(A,

6,

C,

D)

with a soldering iron; (do not apply the soldering iron to the terminals for a long time or

diodes)

72)

it

will damage the

a

(1)

Do not keep the unit in storage under dusty,

damp, and high temperature conditions.

In case dust, dirt, water, oil, etc. are

(2) posited on the generator and lead connections, clean the necessary parts before use.

Keep the appropriate belt tension, to avoid

(3)

belt slippage.

[Current Limiter] This is used coupled with the generator. Refer to

the section on the generator, for the specifications, diagram, and handling instructions.

Current limiter forms one unit contained in resin mold. In the case of a failure, replace current

limiter

as

a unit.

de-

Remove the set screws

(4)

diodes.

(5)

Remove the set screw (d), and remove

armature coil

[Assembly] Follow the instructions above reversely.

6.

MAINTENANCE AND INSPECTION

(el.

(h),

and proceed to

[Inspection of Current Limiter]

Checkthecontinuity between the red lead

black lead with a tester.

No

continuity

Lead Iblack)

I

an-

Set

-.

screw

id1

7

Flywheel (a1

OC (+I

red

ENERATOR IGP8108)

7.

STARTER

(1)

Specifications

Manufacturer

I

Manufacturer's code Yanmar'r code Out~ut/weisht kW/lbs (kWIkq1

Mesh

method

Light running Terminal voltage

Lock torque

I

Tvoe

of clutch

Pinion Diametric pitch

MOTOR

Speed (rpm1 Over 7000 Over 6000 Terminal voltage (Vl/current (Al Torque 1k9-m1

Spring tension Standard lengthlwearlimit in. lmml

Item

(Vllcurrent (Al

or

module/No. of

gear

teeth 10

-

Before serial

HlTACHl

1

S114-196

I

124060-77010

1

1.0111.2211.015.1~

(

51lerr than 330 Slless than 540

Over 6.50 ft-lb

(Over 0.9

DPm

111

/

3.52 1bs (1.6kg)

1

0.63010.157 (16141

Specifisationr

No.

51000

kg-ml

l~fter serial

I

1

S114-219

124060-7701 1

1.2113.2 (1.3161

Over 11.56 (Over

I

1

No.

c

1.6 kpm)

c

51001

I

ft-lb

I

Outer

diamerer 1.575 in10.079

in

I40 mm12 mml

,---.

(2)

Description of Starter Motor

The major components of the starter motor are the magnetic switch section, the motor proper section, and the pinion section. The magnetic

switch section has a plunger which activates

a

shift lever to engage and disengage the pinion, and also open and close the main contacts to start and stop the starter motor.

The over-running clutch

is

provided in order to cut off the motive power from the engine when the engine starts up.

0.4909-0.4902 inl0.4932-0.4921

-0.032 mrn112.5+0.027 mm

'12.5-~.~5~ rnm

(3)

Inspection and Maintenance

o

a) Pinion

The pinion will spring out when the

1)

is

magnetic switch

Push the pinion that has sprung out

21

closed.

towards the motor to eliminate any axial

play, and measure the clearance between the end of the pinion and the pinion stopper.

in.

If

the clearance I is incorrect,

it

should be

corrected by removing and refitting the

justing plate of the magnetic switch mount.

ad-

b) Brushes

Put the brushes in their respective brush holder and measure the spring tension with

a spring balancer. Tension should be more than 3.52 lbs (1.6 kg).

2) Length of Brushes

-

..

.

should be between 0.0197-0.0315 in.

0.8 mm). Be sure to bevel the edges of the bar segments.

0.0197 -0.0315

(0.5

-

(0.5-

in.

0.8mm)

I

Bevel

wment

I

,--.

c) Armature

Standard brush length .is 0.630 in. (16

If any of them are worn out by more than

0.157 in. (4 mm), it should be replaced with

a

new one.

After replacing, check that the new brush moves smoothly in the brush holder, and that the end of the brush makes even contact with the commutator surface. If the contact is uneven, correct

3) Brush Holder Continuity Test Carry out a continuitytest between the in-

sulated brush holder and the ground. There should be no continuity.

1)

Measuring Shaft Straightness

Place the shaft upon an end supporting stand, and measure the straightness of the shaft.

it.

mm).

4) Ground Test Check conductivity between the commuta-

tor and the cated, there

. .

5)

Insulation Test

Shorts in the armature coil are checked

a

with

is

an iron piece applied to the armature

core and the armature while the latter

is

rotated. If the iron piece starts vibrating

or "growling!',

is

a

short, and that replacement

&aft

is

"growler tester." A "growler tester"

If conductivity

a

short, so replace.

it

is

an indication that there

is

indi-

necessary.

/-.

it

is

If (0.08 mm),

2)

If the surface

be polished using

If (0.2 mm), lathe.

3)

The amount of under-cut of the insulation

(mica between commutator bar segments)

distorted by more than 0.0031 in.

it

should be corrected.

Commutator

is

burnt or pitted,

#500-+600 sandpaper.

it

is out-of-round by more than 0.0078 in.

it

should be turned down on

Depth of Mica between Commutator

Bars

it

should

a

d) Field Coil

1)

Continuity Test

Check the continuity between the terminals

is

of the field coil. If there

it

is

an indication that there

the winding, so

2) . Ground Test Check the continuity between either of the

terminals of the field coil and the yoke. If there

field coil

therefore defective.

is

it

should be replaced.

continuity,

is

grounded somewhere and

no continuity,

is

a

break in

it

means that the

is

e) Magnetic Switch

Continuity Test for Shunt CoilISeries

1)

Coil

Continuity of the shunt coil

a

taking

reading between its S-terminal and

is

checked by

the body of the magnetic switch.

is

no continuity, then there is a break in

the shunt coil winding.

Switch

\

-

If

there

is

Continuity of the series coil

checked

between the S-terminal and the M-terminal.

If

there is no continuity, there is a

in the series coil winding.

f)

Performance Test

1)

Connections for Continuity Measurement of Dimension

2)

No-Load Performance Test

I.

break

Battery

Q

@

Battery

0

Switch

/n

v

1

Stamr motor

The diagram above shorn connections to

be

made

for

dimension

the purpose of measuring

I.

'

s

M

Starcer motor

N~Ioad performance using

the

Readinas obtained mu- meet rated

circuitry shown above.

ten

is conducted

V:

A:

DC

voltmeter

DC

ammeter

(25A1

A

8.

THERMOSTART

(1

Specifications

Votage

Current flow

(Optional)

Specifications

SH10002 LHitachil magnetic

valve

type

Setting thermostart switch to OFF posi-

e) tion will switch off the electricity and the heater will cool off. This will close the ball valve.

f)

Fuel will cease to flow. Fuel is stored in

header tank, and

gravity.

(3)

Using the Thermostart

Throttle lever

a)

b)

Decompression lever

is

fed to thermostart plug by

is

set to STOP position.

is

operated.

(2)

Description of the Thermostart

The thermostan is a starting aid for use in low

It

ambient temperatures. in the intake manifold to warm the air intake and improve starting qualities. Thethermostart, unlike glow plugs,

-

of the engine during operation and therefore pro-

vides outstanding durability, and since

tricity requirement is lower than that of glow plugs, the load on the battery

Fuel

is

not exposed to the combustion heat

ignites and burns fuel

is

reduced.

--

Ball

valve

t eater

Terminal

coil

\

its

elec-

Clutch pedal

C) tor is operated for five seconds (until lube oil

indicating light goes out).

Restore decompression lever to position

d) providing compression.

Open the throttle about halfway.

e) f) Press the thermostart switch for

seconds. OR

i) Turn the main switch to the

position for

Then turn the starter motor.

ii)

As soon as the engine starts up, switch off

g) the thermostart, and of course, remove your hand from the starter key switch (the main

switch will automatically move from the

START to the ON position).

is

depressed, and starter mo-

5

-

10

seconds.

5 - 10

"TS"

a) Thermostan switch

activates the heater coil.

b) Valve stem moves. This opens the ball

valve.

Fuel flows through ball valve, and volatil-

c)

izes because of heat from heater coil.

Volatilized fuel is ignited by ignitor.

d)

is

set to ON. This

Main Switch

9

TURN SIGNAL LIGHTS (OPTIONAL)

Description of the Water Temperature System

(2)

(1) Specifications

Flasher relay

(2) Description of the Turn Signal. Lights

The turn signal light system

12V-23W heat band snap type

is

composed of the

:

turn signal switch, the flasher relay, and the signal

lights. The flasher relay, a heat band snap

type,.opens and closes a pair of contact points through expansion

rejulting from a rise in temperature of a

heat band.

Turn

nTurn

0

signal switch

signal light

i

IL)

-

A sensor consisting of a substance with a high

heat expansion rate

and goes

248"

Therefore,

F

(120°C).

ON

when the water temperature reaches

it

is

fitted at the tip of the unit,

is

quite normal for the water temperature indicator light to stay off even if the starting switch

is

set to the

ON

position, as long

as the engine is cold.

11.

ENGINE LUBE OIL PRESSURE INDICA-

TOR LIGHT

(1 ) Specifications

1

tern

I

Oil prersur~rwitch

Lube

oil

indicator light..

pressure

I

Activating pressure 2.W psi I1 kg/cm21

Specnflcattons

.

12v - 3.4.w.

. .

1

I

Flasher relay1 (60--120lmin.)

I

J

Banew

10. WATER TEMPERATURE INDICATOR LIGHT

(1) Specifications

Item

Water temperature

indicator light Water temperature

sensor unit:

~ctivating temperatire

Electrical capacity

Specificadons

12V-3.4 W

ON

at 24~~i5.4~~

(120°u0c)

OFF at ~33.6~i5.4~~)

11 12°u0~1 12V-7A

(2)

Description of the Lube Oil Pressure In.

dicator Light

As described earlier in Chapter

Chapter

VII, Section 11, the lube oil pressure reg-

V,

Section 13 and

ulating valve, which is fitted inside the lube oil filter (cartridge type) 56 psi (1.5

-

2.5 kg/cm2), while the relief valve is set to activate at a pressure of 17.07 psi

(1

2

0.2 kg/cm2

The lube oil switch

is

adjusted to 21.34 - 35.

-

11.38

1.

is

fitted in the lower part of

the cylinder block, to the left of the lube pipe.

It is activated when the lube oil pressure drops,

which simultaneously turns on the indicator light. The oil pressure forces the diaphragm ,upwards.

to open the contact points, so that when pressure

is

normal, the indicator light remains

..

OFF.

..

When the oil pressure drops, the contact points

close to allow electricity to flow to turn indicator light.

Thus, when the starting switch

ON

position, the indicator light goes ON since.

.

..

. .

is

moved to the

ON

. .. .

thk

there

is

no oil pressure, but once the engine starts

up and pressure rises, the light will

go

OFF.

13.

LIGHTS

(1) Headlights

12. HORN

(1) Specifications

/--

(2)

Horn

Description of the Horn

Lube

12V-1.2A

oil

pressure

1

The headlights are high-low beam dual ment bulbs. Switching between low and high beams

(2)

The work light fender.

14.

The safety start switch safety of the tractor and prevention of accidents. When the clutch pedal the clutch, the safety switch incorporated in the starter motor system circuit closes to facilitate starting of the tractor.

is

accomplished by the lighting switch.

-

Headlights: 12V

Work Light (Optional)

is

Work light:

SAFETY START SWITCH

12V - 20W

25W125W

fitted to the rear part of the left

is

. .

is

provided for added

depressed, disengaging

fila-

When the horn button is depressed, electricity

flows through the coil of the horn, the core of the coil

towards the core, and the diaphragm that

coupled to the plate moves and opens the contact points. The flow of current Through a repetition of this cycle, the vibrator

vibrates to generate sound.

is

magnetized, the moving plate is drawn

is

therefore cut off.

Moving plate

I

Diaphragm

core

J

Adjusting nut

is

X.

1.

TRACTOR CONSTRUCTION AND MAINTENANCE

CLUTCH

AND

RELEVANT

ITEMS

The clutch serves to engage or disengage the power generated by the engine with the power train, and also

se~es as a shock absorber the

power train and the engine from being subjected

excessive loads.

to The clutch fitted on this tractor is a dry, single

type.diaphragm clutch.

plate with light pressure and

It

can be operated

it

provides positive en-

gaging and disengaging of the motive power, yet

it

is

also endowed with more than ample dura-

bility and capacity.

(1)

Specifications

(2)

Operating Principle

When the clutch pedal is depressed, the bearing

is

sleeve

moved through a clutch pedalPconsisting

of the clutch rod, the clutch release shaft, and the

clutch shift yoke. The release bearing moves the diaphragm spring

(release lever), weakening the

prekure

of

the diaphragm spring, to disengage the motive power of the engine from the power train.

The torsion springs serve to prevent chattering or

jerks when starting, and also smoothen the trans-

mission of torque.

7.09

Damper

x

4.92

x

wring

0.33

plate

in.

(180 x 125

x

8.4

mm)

Pressure

plate

,-

;

-

3)

ence.

o

Check the torsion springs for wear or breakage.

0

Check the damper plate for wear.

o

Check the splines for wear.

0

Check the pressure plate for distortion of

Visual Inspection friction surface, scratches, or ridge forma-

tions.

o

Check the friction disc for traces glazing, burning, discoloring, or oil adher-

of

scoring,

o

Check the release bearing for traces of burning or looseness.

(4)

Inspecting

Item

1.

Friction disc

thicknerr

2.

Depth of rivet !head

3.

'~hicknerr of

assembled clutch dbc:

[When assembled]

I[UnderpresrureI

4.

Disc play: Axial Within

Radial

Friction

5.

flatness

6.

flatness

7.

8.

of rotations between main drive shaft and disc splines

9.

end diametei

10.

of flywheel

/pilot

11.

ween

and pilot bushings

12.

disc

Pressure plate

Flywheel flatnen Within

Play in direction

Main drive shaft

Inner diameter

Clearance bet-

drive**

Clutch release lever height

by

Testing Equipment

Standard specification

0.13-0.14

13.51*1.11

0.06 11.5)

0.32-0.34

18.4S.3)

0.31 17.8)

0.01 10.3) 0.03 10.7)

-

Within

0.003 10.07)

I

0~003-0.W7 10~07~0~17)

0.5880--0.5887 115-0.M7

-0.065)

0.5892-0.5899 115-0.016

-0.034)

O.DOO5-0.0019

10.013-0.M91

!

cYM155, YM155D1

1.34--1.42 134-361

[YM135, YM135D1

1.42-1.50 136-38)

Replacement limit

0.012 10.3)

0.29 17.4)

-

Within

0.016 10.41

0.008 10.2)

I

0.012 10.3)

-

1

0012

i

Lea

than

I

than

1.26

1.50

1.34

1.61

132)

More than

138)

Less

134)

More

141

Calipen

/Calipers

1

I

Calipen

IDial gauge

Dial gauge

I

Dial gauge

1

Micym~

Cylinder gauge

I

Block gauge

I

a

/:

.71

-

Unit: inch lmml

Illustration

NOTES:

Measure the height

(I)

of

the release lever

(diaphragm

spring

ring).

Ixem

12

above,

in

the following manner:

Insert a 0.331 in

.ij

Attach the clutch cover

iij

The height from the face

iiij

be measured with a pair of calipers and a

The clearance referred to in Item 21 above.is adjusfed after the total stroke of the

(21 clutch

pedal and the clutch pedal play have been properly adjusted.

2.

TRANSMISSION AND RELATED ITEMS

The motive power of the engine is transmitted to the transmission via the clutch.

(8.4

mmj blockgauge in place of the friction disc.

to

the flywheel face and properly tighten

of

the flywheel to the tip of the release lever should

smighr scale.

The Model are capable of being operated in a wide range of speeds, (six forward speeds and two reverse speeds), through the combination of its gear shift

lever and. range shift lever. In addition, in con-

junction with operating speeds are available for the power take

off.

A

one-way clutch

shaft which is an extension of the

shaft, so that if implement side, this load is completely disen-

gaged from the transmission side

sideration contributing to safer operation.

YM135(D) and YM155(D) tractors

its

speed shifting system, two

is

provided on the connecting

a

sudden load

P.T.O.

is

applied from the

-

driving

another con-

,-.

(1)

Specifications

NOTE: /New]

=

Afrer

SeriolNo.

51001:

/Old/ =Before Serial No.

51000.

(2)

Visual Inspection and the final reduction gear housing.

Check to see that there are no traces of

(1)

oil leakage or cracks in the transmission ing.

(2)

Check to see that there are no traces of

oil leakage or cracks in the rear axle housing

[Servicing Standard for Transmission Section;

hous-

(3)

Check the gears for uneven wear, chipped

teeth or cracks.

(3)

Inspecting

Refer to the instructions and detailed drawings in Section the transmission.

by

Testing Equipment

2,

Chapter XI for details on assembling

[Unit: inch (mm1l

No.

1. ([~eedle bearing in main shaft1 Outer diameter of

shaft

Inner diameter of main shaft

Item

maln change

1

Clearance

I

2. [Reverse Outer diameter of metal

Inner diameter of reverse gear

Clearance

Outer diameter of lnner diameter of metal

gear1

countershaft

Standard specification

I

0.5902-0.5906 (15_gol1)

After the Serial No.51001

0.8270-0.8276 (212::;:) Before the Ser~al ~0.51000

0.8257-0.8265 (21100:gi)

After the Serial No.51001

1

Before the Serial No.51000

1

0.9826-0.9835 i251#%$

0.9843-0.9851

/

0.0008-0.0025 (0.020-0.062)

/

0.7869-0.7874 (20-0,013)

/

0.7882-0.7890 (20+0.020)

(25+Eo21)

0

M.041

Replacement limit

I

1

0.006 (0.1 51

I

0.006 (0.151

1

0.01 18 (0.3)

Testing equipment

Micrometer

Cytinder gauge

Micrometer

Cylinder gauge

Micrometer Cylinder gauge

,--.

3. 1 [Lowhi reduction gear341

lnner diameter of low-hi

reduction gear

I

I I

Clearance

I

Outer diameter of connecting

shaft

-

Inner diameter of bushing 0.3939-0.3945

1

/

I

,

0.9843-0.9851 125

0.0003-0.0016 (0.007-0.041)

0.3920-0.3924

0.0001 -0.001 0 (0.003-0.025)

M.021)

,lo$::$:)

(lo$:$;:)

1

0.008 (0.2)

0.01 18 (0.3)

Micrometer

Cylinder gauge

1

Micrometer

Cylinder gauge

I

5. Backlash for all spur gears

7

6. Deflection for all shafts, except differential lock shah

Standard specification

0.006-0.012 10.15-0.3)

Replacement

1

0.02 (0.5)

limit

Testing equipment

Dial gauge

Calipers

Thickness of shift fork tip Clearance

1

.-

8. Outer d~ameter of fork shafts llnner diameter of shift forks

-

Free length of shift fork springs

9.

Fitted load of shift fork springs Fitted length of shift fork spring!

10. Free length of low-hi shift fork spring

Fitted load of low-hi shift fork

spring

Fitted length of low-hi

fork spring

(countershaft) and spiral ring

shift

-

11.66-14.44

0.4528-0.4724 (11.5-12)

15.50-21.32

lbs (5.29-6.55 kg)

lbs 17.03-9.67 kg)

I

8.33 lbs (3.78 kg)

9.04 lbs (4.1 kg)

1

Calipers

Micrometer Cylinder gauge

Calipers

Dial gauge

pinion and ring gear

13. Backlash of differential

pinion and differential sidegears

pinion

Clearance

pinion liner

a: adjusting shims: 0.004 and

0.012 (0.1 and 0.3)

0.004-0.008 (0.1 -0.21 0.020

10.5)

Dial gauge

Cylinder gauge

Micrometer

Calipers

No. Item

16.IThickness of the differential side gear spacers

17.

Outer diameter of metal

22 x 27 x 22.5

I

Standard specification

I

0.035 (0.91

0.039

(1.0)

0.043 (1.1)

0.047 (1.2)

1.0609-1.0622 (27$:00230)

[Unit: inch immjl

I

~eplac&e"t limit I Testing equipment

I

1

0.028 (0.71

0.031 (0.8)

0.035 (0.9)

0.039 (1.0)

I

.

I

Cali~ers

Micrometer

(

lnner diameter of the different-

ial housing Clearance

I!

18.

Outer diameter of the final reduction pinion

lnner diameter of metal

22 x 27 x 22.5

Clearance

--

19.

P.T.O. shah deflection (at tip)

Play in direction of rotation

20.

between all splines

NOTES:

[I)

ball bearings and needle bearings. If there is any looseness, or

heard when turned, or

Particular care shouki be taken nor cracked or chipped.

gears and shaft

Check to see that rhere is no looseness between the inner and outer faces of the

1.0630-1.0638 (27

0.0008-0.0029 (0.020-0.074)

0.8641-0.8654 (2250,053)

0.8661-0.8674 (222031

0.0007-0.0033 (0.020-0.086)

if

it does nor turn smoothly, replace.

in

the case of needle bearings to see that the rollers are

+0.021)

0.020

I

0.012 (0.3)

if

any abnonnal noises are

Cylinder gauge

I

Micrometer

Cylinder gauge

Dial gauge

--

I

--

If the gears have any uneven wear, galling, or scoring, they should

(2)

replaced.

ltem 11 through 16 refer to measurements

(4)

of the differential assembly; ltem 12 is carried

at

a

out

point 90" from the axial direction of the

motive power rotation shaft. Adjustments should

be made in the following manner:

When the =me drive pinion is reversed,

i)

use the shims that were fined initially.

When using a new ring gear and pinion:

ii)

a)

Insert shims [(two sizes are available:

0,004, 0.012 in.

transmission ,case and the front cover

(0.1, 0.3 mm)] between the

transminion case

so that there

is

no space

on

the 0.004, 0.012 in. (0.1, 0.3 mm)] between the

be

repaired or

A

Counter

shaft

arzy

counter shaft.

Fit the differential assembly into the

b) final reduction gear case.

C)

Insert shims [(two

sizes

are available:

baii bearing 6207 (right hand) and the circlip 72 so that the backlash (Item 11)

0.005 - 0.007 in. (0.13 - 0.18 mm). At this time take care to see that there

d)

is

no space between the differential housing and the ball bearing 6207 (both sides), the differential bearing case and the ball bearing 6207 (left hand).

Measure the clearance C between the

e)

final reduction gear case and differential bearing case, and insert the shims:

0.004 in. (0.1 mm) between the final reduction gear case and differential bearing case.

-

C - C

is.

+

.

Transmission

Shims

0.004. 0.012

10.1, 0.3

rnm)

in.

case

[Detail

A1

Angular

ball

bearing

-

/

~i'fferential

Differential

3.

BRAKE

The brake serves not only to bring the tractor to a halt when in motion, but the left and right brakes of the tractor operate independently of each other and allow the operator to negotiate tight turns. The brake shaft of the tractor fitted behind the differential lock shaft and

hermetically sealed to prevent water from enter-

is

ing when the tractor

The brakes are the internal expansion, mechanical type. Foot pressure forces the brake linings against the brake drum to brake the tractor. The

used in irrigated fields.

assembly

housing

1s

-

A-

,

brake linings/shoes are of the leading-trailing type, and the same amount of braking force is produced for both forward and reverse motion.

(1

)

Specifications

The parking brake consists of a locking device coupled to the foot brake.

Item

Type Method

Activation

Location Functioning

-

Lining Brake design Brake adjustments Parking brake

(2)

Inspecting and Maintenance

Specifications

internal expansion mechanical

Anchor pin method

Foot pressure Reduction pinion Independent function for left and right sides (may be

Specical woven material

Leading-trailing shoes

Accomplished by adjusting length of the brake

Locking of the foot brakes

brakei

rod

coupled as needed)

Unit:

inch

(mm)

NOTES:

The left and right brake linings are interchangeable, and it

(I)

rotate them from rime to time

In adjusting the brakes, adjust the play by extending or reducing the length of the

(2)

rumbuckle on the broke rod.

to have even brake wear.

is

a good practice to

Always make sure that the play

3

are interlocked and used to bring the machine to

forces for the

which

is

4.

HYDRAULIC LIFT DEVICE

The hydraulic

left

extremely dangerous.

lift

device is for handling imple-

=nd

right side will be uneven and the tractor will pull to one side,

is

the same for each side. Otherwise,

rnents. The hydraulic oil is the same oil used for

the transmission, and contributes greatly to re-

duced maintenance cost since the operator does not have to maintain various types of lube oils.

socalled single-action type hydraulic system

The

lifts implements hydraulically but allows them to be lowered by the force of their own weight.

a

halt

or to ,reduce speed, the braking

if

the brakes

A

(1)

Specifications

3.76 US gals (14.2 illmin. at RPMs of 2700

(2)

Inspection and Maintenance

Chapter

the hydraulic system.

.

1.

2. lnner diameter of the lifting shaft

3.

-

X,

Section 6 for details on assembling

Item

Relief valve pressure (safety

valve pressure)

bushings (left Outer diameter of the lifting shaft 1.1795-1.1803

(left side)

/Clearance (left side)

Inner diameter of the lifting

shaft bushings (right side) Outer diameter of the lifting

shaft (right side)

Clearance (right side)

side1 0 (30+0.0251

I

Standard specification

1138 psi

1.1811-1.1803

(30-0.020) -0.041

1

0.0008-0.0026 (0.020-0.0661

1.3780-1.3795 (35+0.0391 0

1.3756-1.3770 (3510.059)

0.001 0-0.0039 (0.025-0.0981 0.016 (0.4)

(80 kglcm2

0.025

Replacement limit

/

0.016 (0.4)

Unit: inch (mm

Testing equipment No.

Cylinder gauge

Micrometer

I

Cylinder gauge

Micrometer

--

I

~o.1 ltem

I

Standard specification

Unit: inch imr

/

Replacement limit / Testing equipment

h

I

Hydraulic cylinder bore

pp

Outer diameter of hydraulic piston

Clearance

5.

Lifting capacity at lower link

NOTES:

The components of the hydraulic equipme?? are fitted selectively and are precision

(1)

finished by lapping, thus when they have been disassembled for maintenance, rhe

ingpoinrs should be borne in mind..

i) Do not interchange spool;

Check beforehand the number of hydraulic pressure Udj~~hng shims firred, and

ii)

make sure

When assembling, components such as Orings should ahwys be replaced.

iii)

(2)

When assembling hydraulic cylinder:

Be sure

to align the assembly guide marks on rhe lift shaft, lift crank, and lift arms.

the

tip of

the correct number are used in assembly.

2.3622-2.3661

/

(60';')

-

2.3598-2.361 0 (60-0.060 -0.030)

0.0012-0.0063 (0.030-0.16)

More than

(550

kg)

1210

lbs

0.012 (0.3)

follow-

cylinder

Micrometer

gauge

I

Make sure that each section of the system functions properly as it is assembled.

(3)

Also check rhe working pressure of rhe safety valve with a pressure gauge after the final assembly has been complered

5.

STEERING

The steering system

must provide excellent steer-

ing performance during operation. This tractor

has a ball-nut type steering system.

Column

bush

(1)

Specifications

I

Tractor model TVP~

I

Gear ratio

Angle of motion of center shaft

Sector gear module

I

No. of teeth of sector aear on full circle basis

Worm lead

I

Direction of twist of the worm aear Gear oil Oil capacity Outer diameter of steering wheel Steering wheel play

Item

-

Ball

ioint

Oust

cover

-7

Unit: inch (mm)

Specifications

YM155, YM155D

Ball-screw

1

18.9:l

2

x

430

degrees

3.5

~~

~

I

15

.

0.344 (8.731

Left

-~

SAE

0.05

US gals

.

1

#SO

or eauivalent

(0.2

1)

15.75 (400)

1.17-2.0 (30-50)

YM735, YM135D

Ball-screw

1

15.4:1

2 x 410

degrees

3

I

13

.

I

-

0.313 17.9381

I

eft

I

0.05

.

US gals

14.96 (380)

1.17-2.0 (30-50)

m)

I

1

(0.2 1)

(2)

Inspection and Maintenance

The steering gear box heavy use, and there assemble

Backlash adjustment can be done by varying the

-

number of adjusting shims fitted on the side of the gear box.

Steering play adjustment can be done by adjusting the backlash of the gears.

it

for maintenance work.

is

capable of withstanding

is

rarely any need to dis-

By turning the screw to the right, the amount of

play can be reduced. (The standard position

the screw

at which the screw suddenly becomes hard to

turn.)

is

a quarter-turn back from the point

fSr

NOTES:

(1)

Check wherher the drag rod

Check whether rhe ball joints function smoothly.

(2)

is

bent.

6.

FRONT AXLE AND REAR AXLE

go over irregular depressions and mounds, and

it

The front axle is a Lemoine type axle supported also provides good steering qualities. Other fea-

dy a center pin. of the tractor on an even keel when travelling vides high ground clearance and

It

serves to keep the front end tures of the Lemoine type axle are that

it

pro-

is rugged and

over rough terrain where the left and right wheels therefore very durable.

h

(1-1

Front

Axle

Specifications

Unit: inch(mm)

/-.

NOTE:

(1-2)

Rear Axle

Rear axle type Tread adjustment Tire size: Standard

Optional

Standard air pressure:

Standard Optional

The figures

in

brackets

Specifications

Half-floating type

4-stage:

7-16-4PR F.L.S 27 x 8.50-15PR P.D (Turf tire)

25.6 psi (1.8

11.4 psi (0.8 kg/cm" (Turf tire)

[I

are for purrs before Serial No.

YM1351YM735D

23.6-31.5 in (600-800 mm)

kg/cm2)

51000.

YM155/YM155D

Half-floating type

4-stage: 27.6-33.5 in (700-850 mm)

8-16-4PR F.S.L. 8-16-4PR F.D (Turf tire)

psi(l.6 kg/cm2)

22.8 psi(l.6 kg/cm2 1 (Turf tire)

22.8

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

ENGINE DISASSEMBLY

CYLINDER LINERS The

PISTONS

PISTON RINGS

RODS

CRANKSHAFT

CAMSHAFT

CYLINDER HEAD

COMBUSTION CHAMBERS

GOVERNOR

VALVE CLEARANCE

INJECTION TIMING

GENERATOR & CURRENT LIMITER

Cautions

LIGHTS

Horn

SAFETY START SWITCH

CLUTCH

BRAKE

STEERING