Yanmar YM135 Service Manual Download

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Summary of Contents for YM135

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Page 2: ...ccidents and seri ous trouble Always carry out repairs in a scientific and accurate manner 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 as noting down the servicing history of your tractor and keeping maintenance records In order to easily process any claims it is imperative that the full det...

Page 3: ...for disassembly and assembly 71 6 Maintenanceand inspection a1 7 Starter motor 72 8 Thermostart optional 78 9 Turn signal lights optional 77 10 Water temperature indicator light 77 11 Engine lube oil pressure 77 12 Horn 78 13 Lights 78 74 Safety start switch 78 X Tractor construction and maintenance 79 1 Clutch and relevant items 79 2 Transmissionand relateditems 83 3 Brake 89 4 Hydraulic lift dev...

Page 4: ...l valve assembly 6 4 Hydraulic control fork hydraulic control lever assembly 6 5 Auto return rod operator s seat bracket assembly 6 6 Slow return valve assembly n 6 7 Lift arm assembly 6 8 Operational precautionpolnts XI1 Tractor adjustments 141 XI II Tractor trouble shooting 142 1 Engine and related items 143 2 Electricalsystem 145 3 Brake system 745 4 Clutch and related i t e m 746 5 Transmissio...

Page 5: ...l 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 18 P T O shift lever 19 Hydraulic control lever 20 Assist bar 21 Operator s seat 22 Fender 23 Lift link ...

Page 6: ...ft 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 ...

Page 7: ...ent panel 6 Drag rod 7 Nukle arm 8 Bumper 9 Battew 10 Ragiator 11 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 Hydrauliccontrol lever 20 Assist bar 21 Operator s seat 22 Fender 23 Lift link A 24 Top link ...

Page 8: ...ion 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 401Starter motor 41I 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 ...

Page 9: ...12400 28 912200 F L1 3 5 krml2400 1 14 0 k m 2200 13 2700 Fuel system 1512700 rings Scraper rings I 1 Injection pump plunger diameter I In I 0 2756 7mml 1 Engine starting 1 1 Electricstarting Ignition lnjection timing Injection pump type 0 2756 7mml Injection plunger stroke Injectionvalve type 1 Injection valve diameter 1 n Valve t ming I Compression ignition P 24 f lo before T D C Yanmar Bosch PF...

Page 10: ...ty V W V AH U S ga1 Water cooled Cooling Starter motor type 12 8 5 RS2130 KOKUSANI 12 35 SH100 02 HITACHI magnetic valve type Thermostancapacity 1 V A Clutch I Travel Forwardl 1 MPH kmlhl MPH kmlh speed 1st 0 71 1 14 1 0 67 1 071 I 0 44 2 0 1 Cooling system V KW 12 13 Trans mission r Difference in specificarion depending on serial number 12 1 2 Mechanicaldry single plate 7 09 x 4 92 x 0 33 180mmx ...

Page 11: ... Caster Trail 0 0 Tire size Tire pressure Rims al tires 15 4 1 Brakes YM755D 2 5O 0 43 11 mm 18 9 1 wheels PD Tire pressure psi 11 4 0 8 kg cm21 22 8 1 6 kg cm2 Rims 7001x 15DT 5 K 16 Type of main brakes Internal expansion mechanical brakes Parking brake type Lockingfoot brake Lining surface area 1 sq in 16 1 104 cm2 I Lining width x thick n 0 98 x 0 16 x 4 09 25 x 4 x 104mm ness x length o0 0 15 ...

Page 12: ... SPEC1FICATIONS 4 With 3 point hitch 99 2 l2520rnml Difference in specification depending on serial number ...

Page 13: ...SPECIFICATIONS 5 DIFFERENCE IN SPEClFlCATlONSj ance P T O speed r p m Maximum grade Braking distance degree ft 6 2 1 9m 7 2 2 2ml 35O 11 5 3 5171 7 2 2 2m 35O 11 5 3 5m 6 9 2 lm ...

Page 14: ... 2 POWER TRAIN 1 NOTE New indicatesthoseafter No 51001 Old indicates those before No 51000 No of sear teeth 1 ...

Page 15: ...POWER TRAIN 2 YM135 D IYM155 D POWER TRANSMISSION STRUCTURAL DRAWING FRONT TIRE Nore I 0 hold only ro YMISZDIYM135D 2 Shofi nnd geor are combined I DIFFERENTIAL LOCK ...

Page 16: ...foreSerial No 51000 FRONT DRIVING SHAFT 7 KNUCKLE ARM L FRONT AXLE CASE BEVEL GEAR DIFFERENTIAL PINION DIFFERENTIAL SIDE GEAR LOWER FRONT GEAR CASE DIFFERENTIAL PINION SHAFT DIFFERENTIAL HOUSING BEVEL GEAR FRONT AXLE SHAFT FRONT GEAR CASE CAP FRONT WHEELTIRE 2 ...

Page 17: ...POWER TRAIN 4 Yhl135 D YrV 155 D FRONT AXLE SECTIONAL VIEW IAfter Serial No 51001 FRONT DRIVING SHAFT 7 r FRONT AXLE L FRONT AXLE CASE 7 i r K N U C K L E ARM L FRONT WHEEL TIRE J ...

Page 18: ...N EAR AXLE SHAFT FINAL REDUCTION GEAR REAR WHEEL HUB REAR AXLE HOUSING IL FINAL REDUCTION GEAR REAR AXLE HOUSING IRI FRONT P T O SLIDING GEAR LOW HI REDUCTION GEAR LOW HI SLIDING GEAR FRONT DRIVING GEA REVERSE GEAR NSMlSSlON HOUSING REAR COVER P T O SHAFT COUNTER SHAFT 1STlREVERSE 0 REDUCTION GEAR MAIN CHANGE S O REDUCTION SHAFT DRIVEN SHAFT DRIVEN GEAR A L REDUCTION GEAR HOUSING DRIVEN GEAR E WAY...

Page 19: ...TURN TURN SIGNAL SIGNAL WORK LIGHT LEFT RIGHT HEADLIGHT LIGHT SWITCH WATER TEMP NDICATORLIGHT redl WATER TEMP OIL PRESSURE Graan BUTTON SWITCH ...

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Page 21: ...ke and exhaust rocker arm I No 1 cylinder intake and exhaust rocker arm Cylinder head Timing gear case No 2 cylinder main bearing NO 1 cylinder main bearing No 1 cylindercrank Trochoid pump No 2 cylinder crank Oil Oil pan R Cylinder block Suction tube Drainplug 17 ...

Page 22: ...ot water 1 4 Cylinder heaq 4 7 Cylinder block Radiator I r 8 TRANSkllSSION LUBEIHYDRAULIC SYSTEM Hydraulic cylinder Hydraulic stop valve Hydraulic control lever Hydraulicprn tlr L J1 1 outlet urar pump Oil strainer Transmission case ...

Page 23: ...sembly is undertaken a special stand as shown below should be used Please order the stand separately if desired 2 The separation and assembly explanations will be made on the premise that this stand is being utilized 3 A detailed diagram of the separation and assembly stand is as follows ...

Page 24: ...and A Division Instal lation stand 3 Raise the rear tires by turn ing the adjusting bar of both stands A and B Prior to this adjustment loosen the flange bolts of the rear tire rim 4 Be sure to adjust both stands A1 and BI uniformly to ensure that the tractor remains level CAUTION Whenattaching thefront stand A be sure thefront tiresamain in contact with theground Loosenthe two flange bolts and re...

Page 25: ...Y final reduction tLoosenthe oil plug I201to drain the oil I Illustration Pin 8 x 28 Differential lock rod CautionlRemarks Pin 8 x 17 5 Brake rod Pull out the cotter pin 2 x 151 and remove the pin 8 x 281 A Pull out the cotter pin 2 x 151 and remove the pin 8 x 17 5 1 ...

Page 26: ...from the bolts 10 x 651 the two nuts from the bolts 8 x 20 and remove the fender 7 Seat 8 I Opera ores seat bracket Trans mission case Gear I final The operator s seat can be removed by removinq the High pressure pipe Loosen the adapter and re move the high pressure pipe from the hvdraulic cvlinder ...

Page 27: ...Tranr mission case Gear case ass y final reduction Part Name Low pressure pipe I Pull out the wire behind the clutch housing Removethe seven nuts 12 Illustration CautionIRemarks Removethe three bolts 6 x 181and dismantle low pres sure pipe B Be sure not to damage the oil filter when dismantl ing ...

Page 28: ...case from the final reductiongear case CA VnON I Whenpreforming this procedure if the nuts on rhe left and right side at the arrow mark are hard to remove due to rhe exnuded porrion gradually remove rhe transmission case and remove the nurs 2 Arrach these nursfirsr during assembly v 72 13 14 Division Trans mission case Gear case ass y final reduction Part Name Filter Dismantlingthe transmission ca...

Page 29: ...rm L Removethe lift arm set bolt and force off the lift arm L 21 Lift arm R a Remove lift arm set bolt b Removethe two bolts 8x 201 and dismantle the auto return rod support CI Lift off the lift arm Ri Remove the ten bolts 10 x 35 and separate the hydraulic cylinder housingfrom the final reduction gear case L Rsmovethe nuts 18 on the left right side and remove the brake L Rl ...

Page 30: ...ength over 1in 25 mm For example i7ydraulic adapror coverfiring bolr M8 x 451 11 Loosen oil plug 101and drain the oil 2 Remove the 8 bolts 10 x 60 and the 12 x 60 bolt and the two nuts 121 3 Use a plastic hammer to loosen the flanged part and bolt pans Remove with rhe rear axle shaft a s the base Dlvision Brake Gear case ass y final reduc tion Part Name Brake drum Rear axle housing L1 R1 ...

Page 31: ...s cord L Banery ground cord 2WION J Before remo ing the main ireharness first dismantle he barrev plus I cord and he barrev grouild cord I Wl eiz remorin the main ireharness it is recommeizd dfor ease of handlinc not to emove the coni ecrion in he instrumentpanel 72 2 Main wire hainerr Hour merer cable I b Decornpresrion lever lull out the bolt MBx 70 nd remsve the fuel cock ...

Page 32: ...pipe and take out the high pretsure pipe 124 1 r l u e l oil tank Loosenthe 4 nuts 8 to remove the fuel oil tank band and dismantle the 1 NOTE I Remove rhe cock ass wirh thefuel oil rank connected 2 Phoro shows the procedure for rhe YMIjj D rhefuel rank is differentfrom thar of rhe YMI3j D bur rhe disassemblin procedure remains the same 1fuel oil tank I ...

Page 33: ...ack ward 2 Removethe 4 bolts 6 x 10 and remove the propeller shaft CautionIRernarks Removethe instrument pinel in the following sequence 1 Steeringwheel cap cover 3 Take out the 4 bolts 6 x 16 to shift the propeller shaft cover supporter A backward 4 Remove the 4 bolts 8x 20 to remove the propeller shaft 2 Lock nut 14 x 1 5 3 Steering wheel 4 Fusebox 2 screws 5 x 10 5 Current limter 4 screws 6 x 1...

Page 34: ...om the ground 21 Remove the 4 bolts 12 x 2 and remove the front tires 41 Take out the castle nut 16 and extract the center pin 5 Remove the front axle NOTE Photo shows the procedure for YMI55Dand YMI35D but the same dis assemblingprocedure is usedfor the YM155 and ...

Page 35: ...aner 21 Detach radiator hose 31 Detach radiator with fronr axle as an assemblv Cylinder head 4 11 Drain lube oil 21 Removefan belt 31 Detachgenerarar and starter motor 41 Remove air cleaner and rocker arm cover 51 Detachfuel and lube oil piper 61 Detach rocker arm assembly 71 Remove push rods 81 Remove cylinder head nuts Do not forget the nut in the intake rkanifold 1 91 Removecylinder head gasket...

Page 36: ...ar puller 31 Detsh gear c Nore m e hydraulic pump nnd rnchomerer gem unir ere nor derachedfrom rhe gear case but me removed as o unir Whenotsembling remove rhe hydraulic pump md rnchomerer gem unir to make firring easier 2 1 Check the thicknerr and number of the 31 Remove the lube oil dipstick ...

Page 37: ... 3 1 Derach lube ail inlet tube 41 Remove rad bolts Caution Cleorly markfo later reference which is No 1 pisron and which ir No 2 pisfon 1 Remove the bolrr 5pcrI 2 Remove hydraulic pump driven gear using a gear puller 3 1 Remove lube oil pump ...

Page 38: ... Item Crankshaft Camshaft Explanation 11 Remove main bearioghousiog 2 1 Remove crankshaft Caution Be curem not to drop the thrust bem ng 11 Remove stopper Removethe bearing weights 21 Removecamshaft 3 1 Removetappets 1 ...

Page 39: ...r l I811 in 30mm below the rop of the linerj b at the center of the liner and c at the lower pan of the liner 2 Whether the roundness of the cylinder liner is within the allowable l i m i t s is deter mined by studying the differencesin readings obtained in Item 1 n 3 The cylinder liner projection is necessaty in order to reduce distortion of the cyl inder liner and also to provide a good fit with...

Page 40: ...ade from LOW X ma terial Aluminum alloy which has good heat dis sipation properties Cyl liner replacer A 1 Visual inspection a Extmct the cylinder liner with a cy1inde r Check the pistons for scoring or cracks Also liner replacer check the piston ring grooves for chips or any wear in their edges b Clean the grooves provided for the rubber packing of the liner 2 Inspecting by Testing Equipment h Re...

Page 41: ... in order b Heat up the piston to 176 212 F 80 to achieve good break in properties 100 C Testing equipment Thickness gauge 3 The piston rings are as follows C Remove the piston pin by tapping it with a lead bar and a hammer No 1 ring Barrel face type Provides and maintains good seal 3 2 Assembly ing properties and carbon crush ing properties also prevents car e a Fit inone of the piston pin retain...

Page 42: ...en rhe pisron rings are being firred in rhe pisron be sure rhat the marking on the ring isfacing up 4 PISTON PIN Item 1 Visual Inspection 1 2 Check to make sure that there are no traces of scoring or unevenwear Piston ring groovesand ring clearance Piston ring end clearance No 1 N O 2 N O 3 NO 4 Standarddimension Replacementlivit 1 Refer to section on pistons 2 lnspectingby Testing Equipment Testi...

Page 43: ...amp forged and the The bushings are checked to see whether there is big end sides have square cuts The small end any scoring or peeling bushings are made of sintered copper and lead alloy and the large end side has kelrnet bearings 2 Inspecting by Testing Equipment ...

Page 44: ... Item 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 0 f the crankshafr obtained by measurements conducted using an oil clemce gauge and or a cylinder gouge As in the case of Item 4 rhe measuremenrs are to be raken after the bolrs have been tightened to the prescribed rorque Standarddimemion 0 0Q59 0 0138 10 15...

Page 45: ... Check the crankshaft visually to see whether there are any traces of scoring marring or cracks 2 Inspecting by Testing Equipment Unit in lrnm Tming equipment lllustGtion Micrometer Micrometer Dial gauge 1 I Cylinder gauge ...

Page 46: ...fr is necessmy do not forget to adjust the filler sections of the crank pins a fter the machining is completed Measure the deflection by placing the crankshafi on a supporting stand 3 Irem 5 will be the difference between Item 2 and Item 4 obtained through mea surements 4 Measuring of end play is conducted after the crankshaft has been fined into posi tion as prescribed 5 The roundness of the main...

Page 47: ...the inner diameter of the main bushingto check that they are properly aligned and not contracted 7 CAMSHAFT A single integratedcamshaft incorporatingthe in take and exhaust cams and the fuel cam is 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 ...

Page 48: ...he read ings obtained by measuremenrs of the two components taken using a micrometer and a cylinder 3 Valve timing and fuel injection timing is shown below T D C 7 B D C 4 The clearance between the rappers and tappet guides referred to in Item 6 above i s the difference benveen the readings for the components taken using a micro meter and a cylinder gauge 5 Replacement of the camshaft ball bearing...

Page 49: ...by Testing Equipment Item 90 degrees 1 2 standsrd dimemion Intake 0 2755 0 2761 7 0 015 O Exhaust 0 2763 0 2775 7 0 020 0 050 0 2736 0 2740 1 17 o 040 0 050 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 Inner diameter of valve guider after assembly Outer diameter of valve Remr Replacementlimit 0 0031 0 08 0 0039 0 1 0 0059 10 151 0 0984 2 5 0 0197 0 5...

Page 50: ...dressed using the seat cutters the valves are lapped i Lapping should be done by using valve lapping compound powder ii Thefinishing of the seat should be done by oil lapping iii Whenfitting the valves back in position do nor mix up the valvesfor No I cyl inder with those of the No 2 cylinder All valves are marked prior to shipment from the factow whether they are intake or exhaust valves and also...

Page 51: ...the a Chamber packing CombustionChambers b Front chamber C Chamber packing When assembling the combustion chamber carry d Rear chamber out the work in the following sequence Note e Teflon gasket that the front chamber has front and rear sides ...

Page 52: ... surface table to check rhemfor straghmess 3 Align the oil port when replacing bushings n 11 INJECTION PUMP AND INJECTION VALVE 1 i 2 3 4 and No 2 cylinders Standarddimension 0 5504 0 5511 14 0 018 0 0 5518 0 5525 iQ 034 14 026 0 OW6 0 0020 0 016 0 052 6 5157 165 51 Item Outer diameter of rocker arm shaft Inner diameter of rocker arm bushing Clearance beween rocker arm shaft and inner diameter of ...

Page 53: ...cam shaft 2T73A 22ccl l W k t at 1250 2 Disassembly Assembly Adjusting 2 1 Fuel Injection Valves a The injection valves are built as shown in the illustrationbelow Valve spring reminer Adjusting shim Valve holder body Valve spring shoe Fuel injection valve S Y ...

Page 54: ... be generated more than 7 112 5 psi1500 kg cm2 c Whenever any of the plungers have to be 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 DISASSEMBLY SEQUENCE NO 1 CYLINDER Delivery valve spring Delivery valve holder J Plunger guide roller pin 2 Plunger guide roller Delivery valve sea ...

Page 55: ...ion 15 Plunger barrel packing NO 2 CYLINDER 16 Fuel control pinion screw Check scribed line 17 Plunger guide roller pin Rungr guide d l e r outer Plungerguide mllcr Rungerguide roller inner 18 Same procedureas 3to 7 19 Sleeve 20 Same procedure as 8 to 151 21 Fuel control pinion 8 22 Rack not mix up the parts for the No 1 cylinder and No 2 cylinder Keep the pam for each cylinder 1 Do not mix up com...

Page 56: ...ed in the correct direction 8 Fuel control pinion A Line up alignment marks 9 Plunger spring retainer Check which side should be up 10 Plunger spring 11 Plunger Lineup alignment marks 12 Plungerspring lower retainer 13 Plunger positionadjustingshim Adjust the plunger to close the port of barrel by the shim s inwhich pre fit volume is 0 098 2 5 mm 14 Plunger guide 15 Plungerguide roller NO 2 CYLIND...

Page 57: ...travel through the governor lever and inkage to move the rack of the fuel pump In addition this engine is equipped with a rt orque spring t o increase the amount of fuel supplied as neces sary 13 LUBRICATING OIL PUMP 1 Pump A trochoid pump is used for the lub icating oil pump Inspecting by Testing Equipmentj i Unir in lmml Item Clearance between outer r01or and body Clearance between body and inne...

Page 58: ...measure their respective backlash readings 2 Visual Inspection Unir in mml Check the gear tooth faces for pitting and if any gear shows severe pitting replace it Item Backlash 3 Tachometer Gear Unit only model 2TR13A engine Check to make sure that the gear unit functions smoothly 16 OIL SEALS O RINGS AND BALL BEAR INGS Standarddimension RePImment limit o Crankshaft fined on both ends Flywheel side...

Page 59: ... bearing housing Ascertain that crankshaft turns readily Crankshaft side gap Remark I D 7T Hard Reel 5 8 8 7 ft Ibr 0 8 1 2 kpm 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 d2 15 kg m 12 152ft lbr 17 21 kg m 174 210ft lbs 24 29 kg m 239 297 n l b r 133 41 kpm 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...

Page 60: ...Cylinder block is stood on its end with flywheel end below 11 Pinon assemblies No 1 No 2 luringa pinon ring insertion tool dl Mark on md cap is aligned with large bossend Matchsame mark1 ...

Page 61: ...2 Align matching markson the Hydraulic pump drive gear ...

Page 62: ...ne beforethe 0 Lube oil pipe TWO poirnr on the cylinder black 0 Lube oil pressure witch 0 Lube oil dipstick 2 Coat oil real with lubeoil and push fit the crankshaft V pulley raking care not to damage lip section of oil real 3 Lube oil pressurecontrol valve and lube oil filter 4 V pulley to crankshaft 5 Hour meter gear unit 6 Hydraulic pump ...

Page 63: ... bolt 31 Align mark on the rack with datum level of pump by moving injection control shaft towards thegear care 41 Lock injection control 51 Attach rupplementlry oil inlet 61 Anach fuel injection pump cover 1 Fit gasket taking carethat rhe correct side is up Sidewith strips should be visible 21 Push rods 31 Cylinder head 41 Rocker arm assembly 5 Lube oil pipe Looren the adjustment screw before ati...

Page 64: ...i and after adjustment tightened once again 3 The valves for No 2 cylinder are also adjusted t o clearances of 0 0078 in 0 2 mml after turning the engine exactly 180 from the TDC for No 1cylinder where there is comprerrion 11 A C geneator 2 Cooling fan The fan belt should be rightened to the point where it may be presseddown by the fingers 0 4 0 6 in 10 15 mmi at a point midway beween The generato...

Page 65: ...r lever At the same time screw the fuel injection limiting shaft in 5 Lock the fuel injection limiting shaft when the end of the punched mark on the rack is lined up with the datum lever of the pump 6 Attach the fuel pump chamber cover 2 VALVE CLEARANCE 1 No 1 cylinder flywheel side cylinder is set to the TDC position where there is compression This is done by lining up the stamped mark on the cra...

Page 66: ...TDC posi tion where there is compression 2 The flywheel is moved back and forth in small increments 3 The flywheel is stopped at the very moment that fuel is discharged from the delivery valve 4 The angle between the stamped mark on the crankshaft V pulley and the indicating pointer on the gear case at the time fuel is discharged is checked 5 Correct fuel injection delivery timing is when the stam...

Page 67: ... bolts 5 AIR VENTING Bleeding 1 Put fuel into the fuel tank 3 Carry out the same procedure given in 2 with the air venting plug B 14 Loosen the air venting plug of the fuel pump in the same manner as described in 2 to re lease any air 5 Loosen the injection valve side of the fuel injection pipes 2 Loosen the air venting plug A of the fuel filter allow fuel to flow from he plug until the fuel flowi...

Page 68: ...f a spurting sound which indicates injection is taking place is heard the venting is compteted 6 OTHER MEASUREMENTSAND INSPEC TIONS 1 Lube oil pressure 21 34 35 56 psi 1 5 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 a Extract the combution chamber rearand front insert fuse rod through ...

Page 69: ...rent The open circuit voltage of a battery measured across its terminals is 2 0 2 15 volts per cell and neither the size of the battery nor its number of plates has anything t o do with its voltage Specifications Y60 S4LP YM155 155D Y60 S4P YM135 135D 35AH 20 hourrate1 12V 1 2 6 0 6 8 2 0 at full charge 3 5A The capacity of a battery is the amount of elec tricity that can be discharged from a full...

Page 70: ...ps 3 Inspection of the Battery a ElectrolyteCapacity The water content of the electrolyte will evaporate during use or will be reduced in volume because of electrolysis If there is in sufficient electrolyte the battery is liable to sustain damage and it there 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...

Page 71: ...ion 4 Charging perofrmance 51 Rotationfor initial charging Name 8 8 pole magneto revolving type genera tor Components Clockwise viewed fmm flywheel ridel 1000 m m 5000 rpm 12 000 rpm Moie than 8 5A114 at 4000 rpm than 1500 rpm a Stator armature windings i Each coil is connected in series Wire conductors are wound around an 8 pole armature core A ii An aluminum die cast plate has recti fying diodes...

Page 72: ...ng Current Flowing AC electricity generated by the generator is rec battery When the current being charged in t fledin a full wave t o DC electricity red cord creases with the high speed applied of an AC positive and black cord negative 11 waveform generated is cut t o adjust the current through four diodes When it becomes higher being charged b y the action of resistors and zener than the battery...

Page 73: ...han 28V DC Approx less than 28V OC 11 Diode is bad 21 Open circuit in armature between lead red Dicde A lead red No continuiw Normal 1 More than 7A at 14V lwirhout Current limiter1 21 7 2A at 14 15 W lwith current limiter Abnormal 11 Current more than 7A Voltage more than 15 5V 21 No chargingcurrent 31 Chargingcurrent noted but voltage of battery terminal is Iw Causes Current limiter is not operat...

Page 74: ...t hang lead wire Break o f lead wire 1 Resulting Problems 2 DOnot operate at less than the specified speed 3 DOnot tighten belt too tight 4 Avoid shocks and large stresses on the peripheral of the flywheel Burning of generator coil Failure of current limiter I I Broken pulley bearing of generator Distortion of the flywheel I 6 00not operate out of the specified asrembly condition engine operation ...

Page 75: ... the lead wire from each diode ter minal A 6 C D with a soldering iron do not apply the soldering iron to the ter minals for a long time or it will damage the diodes 4 Remove the set screws h and proceed to diodes 5 Remove the set screw d and remove armature coil el Assembly Follow the instructions above reversely 6 MAINTENANCE AND INSPECTION Current Limiter This is used coupled with the generator...

Page 76: ...Al c Speed rpm1 Over 7000 Over 6000 HlTACHl Yanmar r code c I Tvoe of clutch I c I Out ut weishtkW lbs kWIkq1 1 1 0111 2211 015 1 1 1 2113 2 1 3161 124060 77010 Lock torque Pinion Diametric pitch or module No of gear teeth 10 DPm 111 c 124060 77011 Spring tension 3 52 1bs 1 6kg c Standard lengthlwearlimit in lmml 1 0 63010 157 16141 1 c Terminal voltage Vl current Al 51lerr than 330 Slless than 54...

Page 77: ...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 3 Inspection and Maintenance a Pinion 1 The pinion will spring out when the magnetic switch is closed 21 Push the pinion that has sprung out towards the motor to eliminate any axial play and measurethe clearance...

Page 78: ...re than 0 0078 in 0 2 mm it should be turned down on a lathe 3 Depth of Mica between Commutator Bars The amount of under cut of the insulation mica between commutator bar segments should be between 0 0197 0 0315 in 0 5 0 8 mm Be sure to bevel the edges of the bar segments 0 0197 0 0315 in 0 5 0 8mm I Bevel w m e n t I 4 GroundTest Check conductivity between the commuta tor and the a f t I f conduc...

Page 79: ...ween the S terminal and the M terminal If there is no continuity there is a break in the series coil winding f Performance Test 1 Connections for Continuity Measure ment of Dimension I 2 No Load Performance Test Switch The diagram above shorn connectionsto be made for the purposeof measuring dimension I 1 Switch Battery n s M Battery v Starcer motor Q Stamr motor N I o a d performanceten is conduc...

Page 80: ... because of heat from heater coil e Setting thermostart switch to OFF posi tion will switch off the electricity and the heat er will cool off This will close the ball valve f Fuel will cease to flow Fuel is stored in header tank and is fed to thermostart plug by gravity 3 Using the Thermostart a Throttle lever is set to STOP position b Decompression lever is operated C Clutch pedal is depressed an...

Page 81: ...light to stay off even if the starting switch is set to the ON position as long as the engine is cold 1 1 ENGINE LUBE OIL PRESSURE INDICA TOR LIGHT 1 Specifications I Oil prersur rwitch I Activating pressure 2 W psi I1 kg cm21 I 1tern Specnflcattons 2 Description of the Lube Oil Pressure In dicator Light 1 Lube oil pressure indicator light As described earlier in Chapter V Section 13 and Chapter V...

Page 82: ...ed electricity flows through the coil of the horn the core of the coil is magnetized the moving plate is drawn towards the core and the diaphragm that is coupled to the plate moves and opens the contact points The flow of current is therefore cut off Through a repetition of this cycle the vibrator vibrates to generate sound Moving plate I Diaphragm Horn 14 SAFETY START SWITCH 12V 1 2A The safety s...

Page 83: ...otive power yet it is also endowed with more than ample dura bility and capacity 1 Specifications 7 09 x 4 92 x 0 33 in 180x 125 x 8 4 mm 2 Operating Principle When the clutch pedal is depressed the bearing sleeve is 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...

Page 84: ...Check the splines for wear 0 Check the pressure plate for distortion of 3 Visual Inspection friction surface scratches or ridge forma tions o Check the friction disc for traces of scoring o Check the release bearing for traces of burn glazing burning discoloring or oil adher ing or looseness ...

Page 85: ... 003 10 07 Calipen Within 0 016 10 41 IDial gauge I Flywheelflatnen Within 0 003 10 07 0 008 10 2 0 008 10 2 I 0 012 10 3 Play in direction of rotations bet ween main drive shaft and disc splines Main drive shaft end diametei Inner diameter of flywheel pilot Dial gauge I Dial gauge Dial gauge 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 Clearance bet 1 ween driv...

Page 86: ...NOTES I Measure the height of the release lever diaphragm spring ring Ixem 12 above in ...

Page 87: ... The motive power of the engine is transmitted to the transmission via the clutch The Model YM135 D and YM155 D tractors 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 its speed shifting system two operating speeds are available for the power tak...

Page 88: ... 1 Specifications NOTE New Afrer SeriolNo 51001 Old Before Serial No 51000 ...

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Page 90: ...Outer diameter of metal 10 9826 0 9835 i251 0 5902 0 5906 15_gol1 After the Serial No 51001 0 8270 0 8276 2 1 2 Micrometer Standard specification Micrometer Cytinder gauge 0 8257 0 8265 21100 gi 1 Before the Ser al 0 51000 I After the Serial No 51001 Replacementlimit 0 006 0 151 Inner diameter of reverse gear 0 9843 0 9851 25 Eo21 3 1 Lowhi reduction gear341 Micrometer Testing equipment Cylinder g...

Page 91: ...length of shift fork spring countershaft and spiral ring pinion and ring gear 13 Backlashof differential pinion and differential sidegears pinion Clearance pinion liner Standard specification 15 50 21 32 lbs 17 03 9 67 kg 1 9 04 lbs 4 1 kg Replacementlimit I 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 0 006 0 012 10 15 0 3 1 0 02 0 5 11 66 14 44 lbs 5 29 6 55 kg T...

Page 92: ...22 5 2 If the gears have any uneven wear galling or scoring they should be repaired or replaced Micrometer Cylinder gauge 0 012 0 3 Clearance P T O shah deflection at tip Play in direction of rotation between all gears and shaft splines 4 ltem 11 through 16 refer to measurements of the differential assembly ltem 12 is carried out at a point 90 from the axial direction of the A motive power rotatio...

Page 93: ...C 0 004 in 0 1 mm between the final reduc tion gear case and differential bearing case Angular ball bearing i fferential assembly Differential housing 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 1s fitted...

Page 94: ...specting and Maintenance Item Type Method Activation Location Functioning Lining Brake design Brake adjustments Parking brake Unit inch mm Specifications internal expansion mechanical brakei Anchor pin method Foot pressure Reduction pinion Independent function for left and right sides may be coupled a s needed Specical woven material Leading trailingshoes Accomplished by adjusting length of the br...

Page 95: ...the machine to a halt or to reduce speed the braking forces for the left nd right side will be uneven and the tractor will pull to one side which is extremely dangerous 4 HYDRAULIC LIFT DEVICE The hydraulic lift device is for handling imple 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 mai...

Page 96: ...g shaft 1 1795 1 1803 left side 30 0 020 0 041 Micrometer Clearance left side 1 0 0008 0 0026 0 020 0 0661 0 016 0 4 I Testing equipment No 1 Cylinder gauge Standard specification 1138 psi 80 kglcm2 Item Relief valve pressure safety valve pressure Micrometer Replacementlimit 3 shaft right side I Clearance right side Inner diameter of the lifting shaft bushings right side Outer diameter of the lift...

Page 97: ...he correct number are used in assembly iii When assembling components such as Orings should ahwys be replaced 2 When assembling hydraulic cylinder Be sure to align the assemblyguide marks on rhe lift shaft lift crank and lift arms p p 2 3598 2 3610 60 0 060 0 030 0 0012 0 0063 0 030 0 16 Lifting capacity at the tip of lower link 3 Make sure that each section of the system functions properly as it ...

Page 98: ...mount of The steering gear box is capable of withstanding play can be reduced The standard position fSr heavy use and there is rarely any need to dis the screw is a quarter turn back from the point assemble it for maintenance work at which the screw suddenly becomes hard to turn Ball screw 3 5 Oil capacity Outer diameter of steering wheel Steering wheel play Backlash adjustment can be done by vary...

Page 99: ...rted also provides good steering qualities Other fea dy a center pin It serves to keep the front end tures of the Lemoine type axle are that it pro of the tractor on an even keel when travelling vides high ground clearance and it is rugged and over rough terrain where the left and right wheels therefore very durable h ...

Page 100: ...re size Standard Optional Standard air pressure Standard Optional YM1351YM735D Half floatingtype 4 stage 23 6 31 5 in 600 800 mm 7 16 4PR F L S 27 x 8 50 15PR P D Turf tire 25 6 psi 1 8 kg cm2 11 4 psi 0 8 kg cm Turf tire YM155 YM155D Half floatingtype 4 stage 27 6 33 5 in 700 850 mm 8 16 4PR F S L 8 16 4PR F D Turf tire 22 8 psi l 6 kg cm2 22 8 psi l 6 kg cm21 Turf tire ...

Page 101: ...n intersects with the ground and the point at which an imaginary line extending perpendicularly from the axis of the wheel intersects with the ground Toe in The difference between A and B Serves t o improve directional stability Because of the camber angle the left and right front tires each try to roll forward out wardly This is prevented by the tie rods and so a certain amount of slippage is cre...

Page 102: ...8641 0 8654 22 0 020 0 053 0 0016 0 0048 0 040 0 123 3 If there is excessive up and down play of the king pin Item 2 above insert ad ditional upper coverls Replacementlimit 0 0007 0 0339 0 02 0 86 4 When the fronr hub bearing becomes worn rhefront wheels will develop a shimmy a sreering vibration orflutter in rhe vicinity of the kin vin which will impair sreering srabiliry therefore parricular car...

Page 103: ...0014 o 012 lo 31 10 009 0 0361 After 1001 Serial No Before 1000 Testing equipment 7 8 9 10 Replacement limit Standard specification No Backlash of differential pinion and differential side gear Inner diameter of differential pinion Outer diameter of differential pinion shaft Clearance Thickness of differential pinion liner Thickness of differential ride gear spacers Item Micrometer 0 020 0 5 0 004...

Page 104: ...vel gear 28 14 18 181 andbevel gear 20 1271 Clearancebetween bevel gear 14 and king pin bevel gear 28 14 Standardspecification a adjusting shims 0 004 and 0 008 10 1 and 0 21 b adjusting shims 0 004 and 0 012 0 1 and 0 3 0 004 0 012 0 1 0 3 0 004 0 012 10 1 0 3 3 Irem 6 through 11 refer to measurements for the differential assembly Irem 11 Replacement limit 0 024 10 61 0 024 10 61 15 Unit inch mml...

Page 105: ...r axle L and between ball bearing 6207 so that the backlash Item 6 is 0 005 0 007 in 0 13 0 18 mm Front axle ease Front axle I R I l I Bolt M10 Drive pinion Ball bearing 6207 hUFront axle IL Shims 0 004 0 012 Ball bearing6207 A 0 6280 0 6319 in 163 05 mm 0 B 2 8343 2 8316 in 724 01 mml C 2 362 in 60 mm D 4 5669 in 116 mm d At this time be sure that there is no space between the differential housin...

Page 106: ... bevel gear 28 14 18 18 is 0 004 0 012 in 0 1 0 3 mm ii Insert shims two sizes mailable 0 004 0 012 in 0 1 0 3 mm between the bevel gear 20 1271 and ball bearing 6306 6305 so that the backlash Item 13 of the kingpin bevel gear 28 14 18 18 and bevelgem 20 27 is 0 004 0 012 in 0 1 0 3 mm CAUTION I Figures or the end of gear indicate the number of teeth 2 Figures in indicate those beforeSerial No 510...

Page 107: ...uel pump Open the filter cock Bleed the fuel system of air of gear teeth at the fuel pump Attach the return pipe to the fuel injection valves 5 In the event that there are no instructions for installing the oil seal it should be installed NOTE Replace the copperpacking so it is flush with the outer edge as shown in the illustraion 6 Attach the hydraulic pipes NOTES Replace the copper packing on th...

Page 108: ...or its malfunction 17 Apply bond to both sides of the packing 18 The circular ring and circlips sometimes be come weak after they have been removed con sequently check them before assembly 19 The following points should be observed when connecting the housing assembly clutch to both the transmission case and the gear case assembly final reduction a when the main transmission is in the neu tral pos...

Page 109: ... 1231 and the 6 liner 25 x 33 x 1 6 Fit on the 7 circlip 25 Clutch housing side c 3 Fit on the 8 P T O sliding gear 16 19 and fit on the 9 circlip 25 4 To the assembled parts of 1 3 fit on the 11 liner 25 x 33 x 1 6 and press fit the 10 ball bearings 6303 and 12 6205 NOTES a Apply grease to the inner surface of rhe 5 P T O reductiongear Afrer SeriaINo 51001 19T BeforeSerial No 51000 23T b Consmcri...

Page 110: ...n Differences in rhe I P T 0 Fork into the slot on the 2 P T O sliding gear Shafts Those wirh a Senid No after 51001 have 3 After Serial No 51001 16T round slots Before SerialNo 51000 19T 3 Attach the items in step 1 and 2 from the Those wirh a Serial No before 51000 have 5 round slots Transmissioncare 4 O RING P I 1 SHIFTER P T O change STEEL BALL 5 16 SPRING WASH Final reduction Clvrch housing r...

Page 111: ...ng P 41 1 8 1O ring P41 141 Collar 131 Front P T O sliding gear 24 291 71Bearing retainer 120 5x25x401 1 61 Oil real TC20357 I Front P T O shaft 121Ball bearing 6303 1 1 51 Ball bearing 1 1 Clutch housing ride 2 4 Front P T O Shift Shaft Assembly YM 135D YM155D 1 Fit the 4 O ringPI1 to the 1 front P T O shift shaft 2 Place the 3 front P T O shift fork into the slot of the 2 front sliding gear 3 As...

Page 112: ... x 24 5 on one side 9 driven gear 13 10 driven gear 26 and the 51Driven gear 15 1 Collar 2 5 3 2 2 4 5 Clutch housing ride Final reduction 1 71 Drnven gear 18 8 Collar 2 5 3 2 2 4 5 Parts Having a Serial No Before 51000j x 32 x 15 8 driven gear 12 9 driven pear 26 and 10 liner 17 x 30 x1 1 With the 1 driven shaft in the transmission case insert the following from the final reduction 2 Press fitthe...

Page 113: ...0 x 25 x 22 13 r e verse gear refer to Note d 14 liner 20 x 35 x 1 and the 15 collar 21 x 27 x 36 5 3 Press fit the 16 angular ball bearings 7204 b The left and right surface of the inner lace 0 2 double row ball bemMngs are different Inserl bigger side next ro the pinion side as shown h illustration C Be sure to apply grease to the inside of th low high reduction gear 34 and the 13 reverse as wel...

Page 114: ...e Shaft Assembly Those with a Serial No after 51001 hove two slots while those wirhSerial No before 51000 have no slots 1 Onto the 1 main change shaft put the 3 collar 25 x 30 x 11 and the 4 main gear 31 fit b No of reerh on the 5 circlip 25 and then put on the 6 2ndl3rd gear refer to Note b 7 Istlrevene sliding gear refer to Note b and the 8 liner 15 5 x 28 x 1 2 Press fitthe 2 ball bearings 6303...

Page 115: ...om the clutch housing side 4 Place the 3 2nd13rd speed shift fork into the center position NOTES a Construction differencesin the I 2nd 3rdspeed shift shafr Those with a Serial No after 51001 have rwo slots while those wirh a Serial No before 51000 have no slot b A circlip 12 is attached to only I speed shift shafts numbered after Serial No 5I001 0 3 9 10mm 10 45 I1l Srnm 41O RING P l l 31 FORK 2n...

Page 116: ...Re Before Serial No 51000 allfour models 26 versellst speed shift shaft 3 Insert the part in step 1 from the clutch housing side 2 Place the 3 Reversellst speed shift fork into the slot of the 2 Reversellst sliding gear 4 Place the 3 Reversellst speed shift fork into the neutral position center slot 0 49 125mmJ CIuIch housing ride ...

Page 117: ... 15 5 x 28 x 1 and the 4 needle bearing I is thereforerecommended rhargrease be applied to them to prevent dropping rhem Also be sure rhar the 4 needle bearing will bear the load weighr evenly b Difference in shape of the 4 needle bearings Those numbered afrer Serial No 51001 are Needle bearing KT152111 while rhose numbered beforeserial No 51000 areNeedle bearing TLA1512 C Use he 3 liner 16 x 21 x...

Page 118: ...packing between the assembled parts of steps 1 2 and 3 and securewith the 10 copper packing 8 4 pcs and 9 bolts 8 x 20 4 pcs 5 Place the 3 rubber boot in the position shown in the illustration and secure it with the 8 circlip 50 Attach the 1 gear shift lever knob 6 Insert the 19 transmission case upper cover packing between the assembled parts step 1 5 and the transmission case Secure itwith the 1...

Page 119: ...No of teeth AfterSerialNo 51001 14 Before Serial No 51000 15 2 Press fit the 6 ball bearing 6205 into the final reduction gear case From inside the final 16 Ball bearing6205 31 One way clutch B 171P T O reduction gear 14 1151 5 Collar 25 30x34 81 Ball bearing6304 19 Differential lock shaft ring 6 2 14 Connecting Shaft Assembly 2 Attach the parts above step 1 to the P T O reduction shaft step 2 13 ...

Page 120: ...lip 62 and insert the 3 oil seal TC 40628 5 Attach the 11 transmission case rear cover packingto the final reduction gear case 6 To the assembled parts of step 3 and 4 fit the 9 P T O shaft gear 24 251 and the 1 spline slot of the P T O shaft Attach the final reduction gear case and secure it with the 12 spring washer 8 and the 13 bolt 8 x 25 NOTE No of reethforR T 0 shaft gear AfrerSeriarNo 51001...

Page 121: ... liner 20 5 x 29 x 1 5 and 9 differential lock clutch 3 Insert the 10 liner 30 5 x 46 x 1 5 on the 9 differential lock clutch and then attach the 11 differential lock clutch ring and the 12 circlip 20 NOTE No of reeth r 71 Oifferentiallock spring Differenzial lock shaft gear I I5 61 ifferential lock shaft ring r 51 Liner 24 5x29x1 5 I4 41 Differential lockclutch gear 15 YM135 DIl 14 YM155 Dll 21 B...

Page 122: ...ch the 7 seal collar 25 x 35 x I1 to the facing the correct direction n inside of the 0 ring slot b Clean the 13 rear axle shaft and remove any b Fir the oil seal TC35508 so it is flush with the grease from the hexagonal part before firing on the edge of the 24 rear axle housing 15 oil seal TC507010 c i Length of the final reductionpinion L c 13 rear axle shaft length 6 91 in 175 5 mm 16 4 in 416 ...

Page 123: ... A r 4 Ball bearing6206 1241 Rear axle housing 2 5 1 Rear axle housingpacking ...

Page 124: ... x 1 the 5 differential side gear spacers 2 pcs 2 Fit the 7 differential pinion shaft into 11 the differential side gear 14 2 pcs and the place after passing it through the 1 differential 3 differential thrust collar Be sure to put in the housing 6 differential pinion liners 2 pcs the right and left 12 liners 22 5 x 30 x 1 2 pcs 8 differential pinion 10 2 pcs and the 3 the 5 differential side gear...

Page 125: ...18 8 pcs from loosening secure them with 10 wire 0 8 x 180 c Tightening torque for the 9 bolts 8 x 18 17 22 ft lbs 2 3 3 kg m d There me four kinds of 5 differential side gem spacers i 0 035 in 0 9 mm ii 0 039 in 1 0 mm iii 0 043 i n 1 1 mm iv 0 047 in 1 2 mm 7 Fit the 4 ball bearings 6207 2 pcs on the differential housing NOTES a When performing step 2 be careful to line up the shaft and liner ho...

Page 126: ...e 2 rear axle housingcover pack ing to the assembled parts in step 1 Attach the final reduction gear case and secure it with the 6 bolts 8 x 25 NOTES a Attach the I differential cam lock so the spring pin hole is in the horizontal position 3 Use 5 shims 72 x 0 1 72 x 0 3 to adjust o o c r l o o the pinion and ring gear backlash to within 0 005 0 007 in 0 13 0 i8 mm 4 Insert the 8 differential case...

Page 127: ... bevel gear and the 24 ball bearing 6305 to adjust the back lash of the 23 bevel gear 14 and the 19 king pin bevel gear between 0 004 0 012 in 0 1 0 3 mm 6 Remove the 12 king pin 18 thrust bear ing 51105 and the 26 needle bearing25 x 31 x 20 that were attached in step 4 7 Attach the oil seal TC4062126 to the 27 front gear case cap n 8 lnsert the seal ring 34 x 40 x 17 into the front axle shaft 9 A...

Page 128: ...4 0 012 in 0 1 0 3 mm so the clearance between the 9 nut 18 x 1 5 and the 15 spacer 22 5 x 40 x 1 and the 32 plain washer is 0 0 004 in c0 1 mm 8 Attach the 17 bolt 10 x 40 as shown in the illustration 0 43 in 11mml Spring washer 10 17 Bolt 10x40 1 31 Upper front gear case 9 Shim A 25 x 35 x 0 1 25 x 35 x 0 3 3 Both ball bearings 20 and 22 are size Shim B 30 x 45 x 0 1 6205 but since 20 is a one s...

Page 129: ......

Page 130: ...xle assembly step 6 insert the 7 0 ring 1A 2025 6 king pin upper cover 5 feather key 4 knuckle arm 3 plain washer and 2 spring washer 18 Tighten the 1 nut 18 8 Attach the 23 grease nipple and 24 bolt 6 x 4 5 NOTES a Put in the 14 oil seal TC 355211 so it is flush with thefront edge of the case b Be sure to pur in enough grease in the 9 front axle I 7 front wheel hub 20 front wheel hub cover and th...

Page 131: ...ert the 7 oil seal lOOx 120 x 12 to the edge of the 8 lower front gear case 4 Attach to the 10 liner 22 x 41 x 2 3 the larger inner diameter side of the lace of the 9 thrust bearing 51105 5 Insert the 11 bolt 10x 40 as illustrated j 2 3 in dlrnrn 1I Bolt 10x40 4 n I I Spring washer 10 6 Insert the 12 O ring P22 to the edge of the 1 upper front gear case 7 Shim A B 25 x 35 x 0 1 25 x 35 x 0 3 8 Tig...

Page 132: ...1 spiral pinion shaft step 3 into the 9 front axle case NOTES a Insert the 6 oil seal TC 30458 so tis flush 5 Use a mandrel to determine the position of with the end of the 1 51 front axle case the 1 spiral pinion shaft To adjust use front axle shims 0 004 0 012 in 0 1 0 3 mm b Tighrenzng torque 11 bolt 8 x 30 9 IZ ft lbs 1 3 1 7 kg m 6 Attach the 11 bolts 8 x 30 3 pcs 15 13 bolt 8 x 16 17 22 ft 1...

Page 133: ... phre isparallel to the cenrer when press firring the 3 metal 22 x 28 x 22 b Fasten the 7 castle nut so there is no play be nveen the 4 fronr axle case and the 9 front axle bracker in addition the front arle should swing smoothly c Apply grease to the 5 cenrer pin 3 metal 22 x 28 r 22 21 0 ring P22A and I liner 22 5 x 34 x 2 before assembling d Be sure to put the 6 cotrerpin 4 x 30 rhrough the 5 c...

Page 134: ...castle nut 16 2 Insert the 5 center pin through the 1 4 To prevent the 7 castle nut from loosening front axle bracket and the front axle step 1 attach a 8 cotter pin 4 x 30 1 Castle nut 16 8 Cotter pin 4x30 Front C side Y Front ride C 18 Coner pin 4x3 61 Plain washer 16 Front ride C 18 Coner pin 4x3 1 Front axle bracket ...

Page 135: ...n 2 5 mm YM135 5 BRAKE DRUM ASSEMBLY 1 Attach the 2 0 ring S 16 to the 1 brake cam shaft Insert the 3 brake cover and attach the 4 brake cam shaft ring 2 Attach the 6 brake shoe return spring 1 0 the 5 complete brake shoe Attach the brake cam shaft step 1 to the brake shoe step 2 3 Insert the 7 brake cover packing between the step 1 and step 2 parts Attach the 8 rear axle housing and secure it wit...

Page 136: ... 6 HYDRAULIC SYSTEM ASSEMBLY ...

Page 137: ...sembled parts above c lnsert the 22 0 ring P I 4 into the 1 cylinder head lnsert the 24 spring washer 12 4 pcs in the 23 bolts 12 x 35 4 pcs and attach the parts assembled above to the hydraulic cylinder housing NOTE 6 2 Lifting Shaft Lift Arms Lift Crank Hyd raulic Piston Rod Asembly h Parts 7 Srop valveguide 15 Safety v alve plug I6 17 Plug 18 23 Bolt 12 x 35 4 pcs 19 Cylinder pipe 1 lnsert the ...

Page 138: ...n place firring with 19 wire 0 8 x 220 I Punched mark b Tightening rorque NOTE 21 Be sure rhere is no play benveen rhe 6 lifr I Before step 1 align the center of the hole for rhe crank pin and either the 4 liftcrank or the 5 hydraulic 2 bushing with rhe center groove lineof the 1 hydrau piston rod and benveen the 6 I f f crank pin and the lic cylinder case 7 spring pin 5 x 28 ...

Page 139: ...olts 33 40 ft lbs 4 5 5 5 kern c DO NOT rum or take opart the nut or spindle that is attnched to the borrom of the 4 control valve Cylinder head Do not disassemble this portion during regular inspection 6 4 Hydraulic Control Fork Hydraulic Control 2 Place the 5 hydraulic control fork in the Lever Assembly 6 hydraulic cylinder case Insert the assembled parts in step 1 in the 6 hydraulic cylinder ca...

Page 140: ... set bolt NOTE 6 x 30 and then attach it to the 5 hydraulic control fork 4 Insert the 12 steel ball 13 32and 13 lock spring on the 11 lock spring support 5 Insert the assembled parts of step 4 into the 14 final reduction gear case 10 Set bolt 6x 30 6 9 0 8 1 2 9 N u t 6 4 5 0 5 0 7 6 Attach the 15 spring cover packing and 16 lock spring cover to the 14 final reduction ...

Page 141: ...1141 Lifi arm IRI 1 3 1 Nui 6 12 p s 1 181 Csnerpin 3x20 71 Boll 10x35 110 1261SP6w 4 r 110 0 1 ...

Page 142: ... washer 12 2 pcs and 25 bolts 12 x 25 2 pcs 8 Attach the items assembled in steDs 1 7 to the final reduction gear case with the 26 spring washer 10 10 pcs and the 27 bolts 10 x 35 10 pcs 9 To make the 2 auto return stoppers op erate adiust the lift arms R and L to the desired height and tighten the 2 auto return stoppers with the 3 nut 6 2 pcs and 4 bolts 6 x 18 2 pcsl NOTE 6 6 Slow Return Valve A...

Page 143: ...NOTE Be swe ro attach the 2 4 spring washers to both sides of the 3 lift arm Ball rocket I lock pin 2 Spring washer 14 1 41 Spring washer 1 4 6 8 Operational Precaution Points 1 Auto Return Rod The hydraulic control fork s protruding part and the edge of the hydraulic piston will act to stop the lift arms when they are placed in their fur thest position and the lever will return to its center posi...

Page 144: ...tlet a Move the lift arms a little about 10 from the top position completely tighten the stop valve and secure the lift arms b Put the hydraulic control lever in the top position 3 Hydraulic Pressure Divider For the hydraulic pressure divider dimensions refer to the following illustration rO Pressure inlet Unit in Imml return ...

Page 145: ... top link ad just the length of the link and couple the imple ment The top link adjusting lock nut should be on the tractor side 6 Couple the universal joint of the implement to the P T O shaft of the tractor Check to make certain that the stopper pin is inserted properly 7 Raise the implement by setting the control lever to the Raise position and adjust the check chain to control any side movemen...

Page 146: ...ill list the symptoms on a section by section basis and will explain what to do about them When the trouble has been pinpointed and you are about to carry out the work do it prop erly and completely in accordance with the maintenance standards described in the preceding chapters Poor maintenance work will not only damage the establishment s reputation but could also lead to serious accidents so af...

Page 147: ...nce incorrect 5 Overheating Uneventightening or moving components Insufficient coolant Insufficient lube oil 6 Poor fuel oil Trouble Won t start or hard to start Enginestarts but will not run smoothly 1 Insufficient power Remedy Replenish fuel Open fuel cock Bleed air Disassembledelivery valve and clean Replace plunger Adjust governor Lap nozzle or replace Adjust injection pressure or replace nozz...

Page 148: ...k control pressure Check lube oil pressureswitch or replace P I I fumes poor 2 Overheating Reduce load Fault in electrical system 1 Lube oil viscosity is too iow 2 Oil leak 3 Overheating 4 Excessivewear of rings pistons o r 7 High lube oil con sumption 1 3 Improper injection timing 3 Faulty nozzle Lap or replace 4 Excessive lube oil level Check electrical wiring Replace lube oil Replace liners 1 l...

Page 149: ...fficient pinion gap 3 Worn brushes 4 Damaged commutator 5 Faulty armature 6 Faulty magnetic switch contacts 1 Faulty starter motor clutch 1 Faulty starter motor clutch 1 Faulty magneticswitch Worn or damaged return spring 1 Damageto spline section 2 Magnetic switch Poor returning of plunger or worn or damaged return spring 1 2 3 4 5 6 Trouble Starter motor does not Nrn Pinion moves out butdoes not...

Page 150: ...tch rod 1 Return spring worn or damaged Vibration can be felt through the brake pedals Parking brake does not work Parking brake does not return when re leased Brake pedals do not return Probable cause 1 Friction disc scored or burned 2 No effective clutch rod stroke Trouble 2 1 clutch slius I I clutch Adjust 7 Adjust Replace Clutch does not disengage not reNrn 4 Power transmission 1 1 Friction la...

Page 151: ...fficient d d oil Gears adjusted incorrectly relative positions of drive pinion and ring gear not function and return I 4 Fork damaged or bent Replace P T O AND RELATED ITEMS Differential does 1 Differential clutch does not slide IAdiust Differential lack does not function 2 Differential lock spring damaged 1 Differential lock cam damaged Replace Replace Trouble A Probable cause 1 Tractor has not c...

Page 152: ...ng I Push rod does not function Clean or replace smoothly I I 1 2 Stop valve seat seized Replace 3 Rate of free descent Je 3 Hydraulic cylinder piston seized 1 Spool worn lnsufficient free travel when spool is at a neutral position 2 Faulty valve seats D i n i n valve Faulty 0 ring 3 Stop valve 0ring defective Faulty seats 4 Hydraulic cylinder piston or cylinder damaged or worn Broken 0 ring 5 Saf...

Page 153: ...or one side 5 Grease insufficient 1 Joints Excessive backlash in joints gear box pitman arm drag rods knuckle Front tire shimmy Replace Replace Readjust lmproper alignment toe in camber angle caster angle 2 Rods Pitman arm drag rod s1knuckle arms or tie rods bent or deformed Change Adjust 3 Tire pressure Different tire pressures in the left and right wheels 1 Faulty front hub bearings Readjust Cor...

Page 154: ...0 to 1 200 maintenance work listed here be performed hours Inspection and maintenance work should be under the supervision of a Yanmar dealer performed at the intervals indicated below Items Greasing Replace engine lubricatingoil filter Front wheel rear wheel bolts Tighten u O Z 0 0 0 0 O N N m o p n Z Z S Z S 5 8 Z z g g I D P m m F n o _ o _ e o I OZ85E2 E 0 ...

Page 155: ... Fender bolts Seat bracket MI0 bolts MI2 bolts Transmission case nuts Hydraulic cylinder case bolts Steeringgear box bolts Steering nut Fuel pump cap nut 29 33 4 0 4 5 Fuel injection valve nozzleholder body 2 65 80 9 0 11 0 No 6 2 4 6 1 5 9 4 2 Clutch pressure plate bolts Transmission front cover bolts Transmission rear cover bolts Top link hinge bolts King pin bolts bottom YM155D YM135D only Fron...

Page 156: ...TIGHTENING TORQUE BOLT CODE 00000 000000 7 appears on the head of the 7T I 4T No electro deposited coating bolts 12 7T No elenrodeposited coating 71 4T With electro deposited coating 61 7T With electro deposited coating ...

Page 157: ...l 1 Disassembly stand 794200 82350 2 Spring pin removing tool 194200 82410 3 Spring pin removing tool 194200 82420 4 Spring pin removing tool 194200 82430 5 Spring pin removing tool 194201 82440 6 Garage jack Purpose of usage Tractor separation To remove the springpin 3 s x 321 To remove the spring pin 5 5 x 32 To remove the spring pin 4 W x 40 To remove the spring pin 7 s x 40 Lifting ...

Page 158: ...n 13 Booster cable BC 100A diarn ...

Page 159: ...YANMAR DIESEL ENGINE CO LTD A 1 11 1 Marunouchi Chiyoda ku Tokyo Japan Cable YANMAR TOKYO Telex 0222 2310 0222 47 AODl048 ...

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Yanmar YM135, Service Manual

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Summary of Contents for YM135

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