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SHOP MANUAL
YANMARModels YM135, YM135D, YM155, YM155D, YM195, YM195D,
YM240, YM240D, YM330 and YM330D
Tractor serial number is stamped on left side of clutch housing on transmission hous-
ing. Engine model and serial number is located on a data plate attached to right side of
engine for YM135, YM135D, YM155 and YM155D models. Engine model and serial number
is located on a data plate attached to left side of engine for YM195, YM195D, YM240,
YM240D, YM330 and YM330D models.
i
INDEX (By Starting Paragraph)
YM135,
YM135D
BRAKES 210
CLUTCH 130
COOLING SYSTEM 115
DIESEL FUEL SYSTEM
raters & Bleeding 85
Nozzles 90
Thermostart 97
Timing 86
DIFFERENTIAL
Front 16
Rear 185
ELECTRICAL SYSTEM
Alternator & Regulator 120
Starter 125
ENGINE
Camshaft 60
Connecting Rods 71
Crankshaft 72
Cylinder Head 45
Flywheel 78
Oil Pump 80
Pistons & Rings 66
Remove & Reinstall 42
Tappet Adjustment 47
Timing Gears 56
Valves & Seats 48
FINAL DRIVE
Front 15
Rear 200
FRONT AXLE
Four Wheel Drive 4
Two Wheel Drive 1
FRONT WHEEL DRIVE 15
GOVERNOR 101
HYDRAULIC SYSTEM 240
POWER TAKE OFF 215
STEERING GEAR 10
TRANSMISSION 150
This service manual provides specifications in both the Metric (SI) and U.S. Customary
systems of measurement. The first specification is given in the measuring system used
during manufacture, while the second specification (given in parenthesis) is the converted
measurement. For instance, a specification of "0.28 mm (0.011 inch)" would indicate that
the equipment was manufactured using the metric system of measurement and the U.S.
equivalent of 0.28 mm is 0.011 inch.
YM155,
YM155D
210
130
115
85
90
97
86
16
185
120
125
60
71
72
45
78
80
66
42
47
56
48
15
200
4
1
15
101
240
215
10
150
YM195,
YM195D
210
130
115
85
90
97
88
21
190
121
125
61
71
72
45
78
80
66
42
47
57
48
20
202
4
1
20
103
240
220
10
160
YM240,
YM240D
210
130
115
85
90
97
88
21
190
121
125
61
71
72
45
78
80
66
42
47
57
48
20
202
4
1
20
103
240
220
10
160
YM330,
YM330D
210
130
115
85
90
97
88
31
195
121
125
61
71
73
45
78
80
66
42
47
57
48
30
204
4
1
80
103
240
230
10
170
SHOP MANUAL Paragraphs 1-3
CONDENSED SERVICE DATA
YM135, YM155, YM195, YM240, YM330,
GENERAL YM135D YM155D YM195D YM240D YM330D
Engine Make OWN
Engine Model 2T73A 2TR13A 2T84A 2TR20A-X 3T84A or
3T84A-LP
Number of Cylinders 2 2 2 2 3
Bore-mm (in.) 73(2.87) 75(2.95) 84(3.31) 90(3.54) 84(3.31)
Stroke-mm (in.) 75(2.95) 75(2.95) 90(3.54) 90(3.54) 90(3.54)
Displacement-cc 627 662 997 1145 1496
Cubic Inches 38.26 40.39 60.84 69.87 91.29
Transmission -
Speeds Forward 6 6 8 8 8
Speeds Reverse 2 2 2 2 2
TUNE-UP
FiringOrder 1-2 1-2 1-2 1-2 1-3-2
Number 1 Cyl. Rear
Valve Tappet Gap-Cold
Exhaust-mm (in.) 0.2(0.008) 0.2(0.008) 0.15(0.006) 0.15(0.006) 0.15(0.006)
Inlet-mm (in.) 0.2(0.008) 0.2(0.008) 0.15(0.006) 0.15(0.006) 0.15(0.006)
Horsepower at pto ... ... ... 19.8
Battery-Volts 12 12 12 12 12
Polarity Ground Neg. Neg. Neg. Neg. Neg.
CAPACITIES-All capacities are in liters and (quarts).
Cooling System 3.2(3.4) 3.2(3.4) 4.6(4.9) 4.6(4.9) 6.2(6.5)
Engine Crankcase 2.2(2.3) 2.4(2.5) 4.0(4.2) 4.0(4.2) 6.4(6.8)
Front Drive Axle 3.0(3.2) 3.0(3.2) 5.0(5.3) 6.0(6.3) 7.0(7.4)
Fuel Tank 9.5(10) 15(15.8) 22(23.2) 22(23.2) 32(33.8)
Transmission, Hydraulic System and Rear Axle-
Two Wheel Drive 9.5(10) 9.5(10) 15(15.8) 15(15.8) 20(21)
Four Wheel Drive 9(9.5) 9(9.5) 15(15.8) 15(15.8) 20(21)
FRONT AXLE AND STEERING GEAR
FRONT AXLE ASSEMBLY
Two Wheel Drive Models
1. ADJUSTMENT. Refer to ap-
propriate Fig. 1, 2, 2A or 3 for exploded
view of fixed or adjustable tread non-
driving axle. Toe-in should be 4-8 mm
(5/32-5/16 in.) for all models. Length of
drag link should be adjusted to provide
equally sharp turns in both directions.
Front axle should not have excessive
front to rear clearance at pivot shaft (5).
Excessive clearance can be removed
from YM195 and YM240 models by
relocating brackets (29-Fig. 2) closer
^together. Be sure all attaching screws
Fare retightened after adjustment is com-
plete. On all other models, adjust axle
play at pivot by tightening the castle nut
(2- Fig. 1 or 3) on pivot shaft. Be sure to
install cotter pin to prevent nut from
loosening after adjustment is complete.
Front wheel bearings should be
removed, cleaned, inspected and renew-
ed if damaged or repacked with new
grease after each 300 hours of opera-
tion. Tighten the hub retaining castle
nut, then lock position by installing cot-
ter pin. Tighten wheel lug bolts to 78-98
N-m (57.5-72.3 ft.-lbs.) torque.
2. REMOVE AND REINSTALL.
Support front of tractor and disconnect
drag link from steering arm. On YM135
and YM155 models, remove cotter pin
and castle nut (2 - Fig. 1) from axle pivot
shaft, support axle with jack, then
remove washer (3) and pivot shaft (5).
On YM195 and YM240 models, support
axle with jack, unbolt pivot brackets
(29-Fig. 2 or 2A) from frame, then
lower axle. On YM330 models, support
axle with jack, remove cotter pin from
castle nut at rear of pivot shaft, then
loosen castle nut (2-Fig. 3). Remove
self locking nut (39), washer (38), sleeve
(37) and snap ring (36), then withdraw
the pivot shaft.
When assembling YM135 model, cas-
tle nut (2-Fig. 1) should be toward rear.
On YM155 model, castle nut is toward
front. Bushings (4) are 25 mm (0.984 in.)
long for YM135 models; 24 mm (0.945
in.) long for YM155 models. Tighten cas-
tle nut (2) on YM135 and YM155 models
enough to remove all axle play;
however, axle should move smoothly
and freely on pivot.
3. OVERHAUL. The steering spindle
(18-Fig. 1, 2, 2A and 3) is equipped
with renewable bushings (13) and some
Paragraph 3 Cont. YANMAR
models are equipped with bearings (15
and 33). Inside diameter of bushings (13)
should be sufficient to provide correct
clearance for the spindle. Adjust spindle
end play by adding covers (11-Fig. 1, 2
or 2A) or shims (40-Fig. 3) as required.
YM135, YM155
Spindle diameter
at bushing 24.948-25.0 mm
(0.9822-0.9843 in.)
Spindle to bushing clearance,
Desired 0.020-0.124 mm
(0.0008-0.0049 in.)
Wear limit 0.4 mm
(0.0157 in.)
Spindle end play,
Desired 0.02-0.086 mm
(0.0008-0.0011 in.)
Wear limit 1.0 mm
(0.0394 in.)
Center pivot pin
diameter 21.947-21.980 mm
(0.8641-0.8654 in.)
Center pivot to bushing clearance.
Desired 0.040-0.123 mm
(0.00157-0.0048 in.)
Wear limit 0.4 mm
(0.0157 in.)
Axle end play on
center pin 0.0-0.5 mm
(0-0.0197 in.)
YM195, YM240
Spindle diameter
at bushing 24.948-25.0 mm
(0.9822-0.9843 in.)
Spindle to bushing clearance.
Desired 0.020-0.122 mm
(0.0008-0.0049 in.)
Wear limit 0.25 mm
(0.0098 in.)
Spindle end play,
Desired 0.02-0.86 mm
(0.0008-0.0011 in.)
Wear limit 1.0 mm
(0.0394 in.)
Center pivot pin
diameter 24.967-25.0 mm
(0.9830-0.9843 in.)
Center pivot to bushing clearance,
Desired 0.020-0.105 mm^
(0.0008-0.0041 in.)
Wear limit 0.4 mm
(0.0157 in.)
Axle end play on center pin,
Desired 0.1-0.3 mm
(0.004-0.011 in.)
Maximum limit 0.5 mm
(0.0197 in.)
YM330
Spindle diameter
at bushing 29.959-29.980 mm
(1.17354.1803 in.)
Spindle to bushing clearance,
Desired 0.020-0.074 mm
(0.0008-0.0029 in.)
Wear limit 0.25 mm
(0.0098 in.)
Spindle end play.
Desired .0.02-0.6 mm
(0.0008-0.0236 in.)
Wear limit 0.7 mm
(0.0276 in.)
Fig. 1 - Exploded vtew of non-adfustabte front ax/e used on YM155 models. Axle used on YM135 Is
similar.
Fig. 2—Exploded view of standard non-
adiustable front axle used on some YM195 and
YM240 models. Refer to Fig. 1 for wbeel bub and
bearings. Refer to Fig. 2A for optional adjustable
axle and beavy duty axle.
1. Cotter pin
2. Castle nut
3. Washer
4. Bushings (25x24 mm for
YM135, 25x25 mm for
YM155)
5. Pivot shaft
6. Frame
7. Nut
8. Lockwasher
9. Plain washer
10. Steering arm
11. Cover washer (40x3 mm)
12. "0" ring
13. Bushing (29x38 mm)
14. Axle main member
15. Ball bearing (6205)
16. Snap ring
17. Seal
18. Spindle
19. Seal
20. Snap ring
21. Ball bearing (6205)
22. Hub
23. Ball bearing (6204)
24. Plain washer
25. Castle nut
26. Cotter pin
27. Cap
28. Tie rod assy.
1. Cotter pin
2. Castle nut
3. Washer
4. Bushings (25x25 mm)
6. Frame
7. Nut
8. Lockwasher
9. Plain washer
10. Steering wrm
11. Cover
12. "O" ring
13. Bushing (29x38 mm)
14. Axle main member 1
15. Ball bearing (6205)
16. Washer (42x51.8x1 mm)
17. Seal
18. Spindle
28. Tie rod
29. Pivot bracket
SHOP MANUAL Paragraphs 4-11
Center pivot pin
diameter 34.95-34.975 mm
(1.3760-1.3770 in.)
^Center pivot to bushing clearance.
Desired 0.025-0.089 mm
(0.0010-0.0035 in.)
Wear limit 0.4 mm
(0.0157 in.)
Axle end play on center pin.
Desired 0.1-0.3 mm
(0.0039-0.0118 in.)
Maximum limit 0.5 mm
(0.0197 in.)
Four Wheel Drive
4. ADJUSTMENT. Refer to ap-
propriate paragraphs 15 through 31 for
service to individual units. Toe-in should
be 4-8 mm for all models.
5. REMOVE AND REINSTALL. To
remove the front axle from four wheel
drive models, first block rear wheels.
Loosen the drive shaft cover clamps,
remove retaining screws, then move
drive shaft cover out of the way. Detach
drive shaft from front axle drive pinion.
On all models except YM135D and
YM155D models, be careful not to lose
the steel balls from drive shaft collars.
On all models, detach drag link from
steering arm. Support weight of tractor
by attaching overhead hoist to front
weight support, then remove both front
wheels. Place a jack under center of
front axle to support axle securely when
attaching screws are removed.
On all models, except YM330D,
remove castle nut from axle pivot, then
withdraw pivot shaft. Be careful to pre-
vent axle from falling when pivot is
Fig, 2A-Exploded vfew of adfustabtB axle awalfable for YMIBS and YfAZAO models. Except for ad-
lustable width feature, heavy duty non-adjustable axle is similar.
26. Cotter pin
27. Cap
29. Pivot bracket
30. Shim
31. Axle extension
32. Axle center member
33. Thrust bearing (51106)
4. Bushings (30x40 mm)
6. Frame
10. Steering arm
11. Cover
12. "0" ring
13. Bushing
17. Seal
18. Spindle
19. Seal
21. Taper bearing (32007)
22. Hub
23. Taper bearing (30205)
24. Plain washer
25. Castle nut
removed, then lower axle away from
tractor.
On YM330D models, disconnect bat-
tery cables, then remove battery.
Remove locknuts (N-Fig. 4) from
screws which attach front axle pivot
brackets to frame. Remove all eight
screws which attach axle pivot brackets
to frame, then lower axle away from
tractor.
When installing, reverse removal pro-
cedure. Be especially careful to prevent
axle from slipping from jack while at-
taching center pivot.
On all models except YM330D, locate
axle in correct position, then install
center pivot pin. Nut should be toward
rear for YM135D models, toward front
for YM155D models. Tighten castle nut
on YM135D and YM155D models
enough to remove all end play, but be
sure that axle pivots freely. Install cot-
ter pin through castle nut to maintain
adjustment. On YM195D and YM240D
models, shims (54-Fig. 23) should be
added to provide axle with less than 0.6
mm (0.0236 in.) end play. Axle must be
free to move and not bind. Coat threads
of the four screws which retain pivot pin
with locking compound after selecting
correct thickness of shims.
On YM330D models, coat threads of
screws which retain axle pivot brackets
with a locking compound and tighten to
149 N-m (109.9 ft.-lbs.) torque. End play
of axle in center pivot brackets is ad-
justed by changing thickness of thrust
spacers (54-Fig. 23). End play should
be less than 0.6 mm (0.0236 in.), but
should not cause binding. Thrust
spacers (54) are available in 2.0, 2.3 and
2.6 mm thicknesses.
STEERiNG GEAR
All Models
10. REMOVE AND REINSTALL.
Remove cap from center of steering
wheel, remove steering wheel retaining
nut, then use puller to remove steer-
ing wheel shaft. Disconnect battery
ground cable from battery. Remove the
battery from YM135 models. On all
models remove the instrument panel
and the fuel tank. Detach drag link from
steering arm, then unbolt, and remove
the steering gear assembly.
Reinstall steering gear, reversing the
removal procedure. Coat threads of at-
taching screws with sealer before in-
stalling.
11. OVERHAUL. Remove cap screws
attaching side cover (16-Fig. 5 or Fig.
6) to housing (21), remove locknut (14),
then turn adjusting screw (15) in to push
cover away from housing. Loosen nut
(25) and turn shaft (6) until gear on
shaft (19) is aligned with opening in
Paragraph 11 Cont. YANMAR
housing. Remove adjusting screw (15),
then bump end of shaft (19) out toward
right. After steering arm (24) is released
from end of shaft, remove nut (25) and
steering arm, then withdraw shaft (19)
from housing. Unbolt steering column
(12), then withdraw shaft (6) and ball nut
(8).
Bushings (22) are available only as an
assembly with housing (21). Seal (23)
should be flush with housing. Inner race
for ball bearings (7) is integral with shaft
(6) and disassembly is not recommended.
Clean ball nut (8) without disassembling
and check for smoothness. Ball nut is
available only as an assembly with shaft
(6). Apply grease liberally to shaft and
ball nut. Grease lower bearing (7) and
position in bearing race located in hous-
ing. Grease upper bearing (7) and locate
on shaft (6). Position shaft (6) with ball
nut (8) and upper bearing in housing
(21). Position column (12) over shaft and
select thickness of shims (13) which will
permit free movement of shaft in bear-
ings (7) with no end play of shaft. Install
column (12) with sealing "0" ring (9)
after selecting correct thickness of
shims (13).
Turn shaft (6) until ball nut (8) is in
center of travel. Coat cross shaft (19)
with grease, then install with center
tooth in center valley of ball nut. Posi-
tion adjustment screw (15) and shim (18)
in end of shaft and gasket (20) on hous-
ing, then install cover (16). Turn ad-
justing screw (15) out through cover (16)
while installing, then tighten the cover
attaching screws to 23-30 N-m
(16.96-22.13 ft.-lbs.) torque. Be sure that
adjusting screw (15) remains loose while
tightening the cover attaching screws.
Install steering arm (24) over shaft
splines with index marks aligned. Some
models have a missing spline to assist
alignment of steering arm. Adjust screw
(15) to provide 30-50 mm (1 3/16-2 in.)
free play at rim of steering wheel, then
lock adjustment with nut (4). Initial ad-
justment can be accomplished by turn-
ing screw clockwise as far as possible,
then backing screw up V4-turn and lock
with nut (14). Wear is indicated if play at
rim exceeds 50 mm (2 in.) with correct
adjustment of screw (15) and correct
thickness of shims (13).
Steering gear should be filled with
SAE 90 gear lubricant. Capacity is 20
mL for YM135, YM135D, YM155 and
YM155D. Capacity is 26 mL for other
models.
Fig. $- Exploded view of adfustable axle used on rM330 models.
1. Cotter pin
2. Castle nut
3. Washer
4. Bushings
5. Pivot pin
6. Frame
10. Steering arm
11. Cover
12. "0" ring
13. Bushings
17. Seal
18. Spindle
19. Seal
21. RoUer bearing (32007)
22. Hub
23. Roller bearing (30205)
24. Plain washer
25. Castle nut
26. Cotter pin
27. Cap
30. Shims
31. Axle extension
32. Axle center member
33. Thrust bearing
34. Plain washer
35. Seal
36. Snap ring
37. Taper sleeve
38. Washer
39. Nut
40. Shims
Fig. 4 "View of nuts {Hi used to iock tbe screws
tbat attacb front drive axle brackets to frame of
yM330O modeis. Nuts are located under battery
bracket
Fig. 5 — Expioded view of steering gear typlcai of
type used on YM135, YM135D, rM155 and
YM155D models.
P. Plug
2. Nut
3. Washer
6. Steering shaft
7. Bearings
8. Ball nut
9. "0" ring
11. Bushing
12. Column
13. Shims
14. Locknut
15. Adjusting screw
16. Side cover
17. Bushing
18. Shim
19. Sector gear and cross
shaft
20. Gasket
21. Housing
22. Bushing
23. Seal
24. Steering arm
25. Nut
10 ^
25
Fig. 6—Exploded view of steering gear typical ol
type used on YM195, YM195D, YM240, YM240D,
YM330 and YM330D modeis. Refer to Fig. 5 for
iegend.
SHOP MANUAL
FRONT WHEEL
DRIVE
OUTER DRIVE HOUSING
YM135D and YM155D Models
15. R&R AND OVERHAUL. The
complete outer drive housing can be
separated from axle after removing
fasteners (A-Fig, 15) or disassembly
can be accomplished before detaching
outer end of axle from center section.
To remove the complete outer drive
housing, remove wheel, detach drag link
and/or tie rod from steering arm and
support axle from tipping. Support
outer drive housing separately, then
remove the two screws and two nuts (A).
Move outer drive housing away from ax-
le center section. Disassembly of outer
drive assembly can be accomplished as
outlined in the following paragraphs.
Some disassembly can be accomplish-
ed with outer drive housing attached to
axle center section. If attached, remove
wheel and support axle from tipping.
Remove the four screws (C-Fig. 16),
then withdraw the axle (1) and cover (4)
from gear housing (15). Be sure to save
shims (7) located between cover and
housing.
Inner bearing (8), spacer (9) and snap
ring (5) must be removed before with-
drawing outer bearing (8) and seal (6)
from around axle (1). Seal wear sleeve
(3) can remain on axle unless new sleeve
is to be installed.
Support outer drive housing and
remove nut (B), washers, shims (34) and
steering arm (35). Unbolt spindle hous-
ing (25) from gear housing (15) and
separate the two housings. Gear (18) and
bearings (24 and 28) can be removed,
cleaned and inspected. Bearings (19) and
spacer (21) can be pressed from housing
(25) if removal is required.
When assembling, upper bearing (19)
is sealed on one side and is identified by
"6305U" marked on side of bearing. The
one sealed side should be down, away
from seal (27), for the uppermost bear-
ing: (19). The lower bearing marked
"6305", not sealed and should be in-
stalled in lower bearing bore. Spring
loaded lip of seal (27) should be down
toward bearing; spring loaded lip of seal
(17) should be up. Inside diameter of one
race for thrust bearings (28) is 25 mm,
the other race inside diameter is 25.2
mm. Install thrust bearings with large
I.D. inner races toward gear (18). Re-
mainder of assembly is reverse of
disassembly; however, shims should be
used to adjust backlash between gears.
Vary the thickness of shims and washer
at (89) to obtain 0.1-0.3 mm
(0.0039-0.0118 in.) backlash between
Paragraph 15
99
Fig, 15-Crosss0ctlon of front drive axie used on late rMY35D and YM1SSD models. Early models
are similar. Refer to Fig, 17 tor legend.
gears (18 and 36). Vary thickness of
shims at (10) to obtain 0.1-0.3 mm
(0.0039-0.0118 in.) backlash between
gears (11 and 18). Shims (34) should be
installed between washers (29) as
necessary to limit the clearance between
bottom of flat washer and the top of up-
per washer (29) to less than 0.1 mm
(0.0039 in.). Do not reduce clearance to
less than zero which would cause the
steering to bind. Turn stop screw (S) as
required so that rear surface of head is
11 mm from rear surface of flange, then
tighten locknut against front surface.
Screws and nuts (A) should be tighten-
ed to 45-58 N-m (33.19-42.78 ft.-lbs.)
Fig. 16—Exploded view of
outer drive housing used on
late YM135D and YMiSSD
models. Early models are
similar, inner bearing (8) Is
S305 on early models. Refer
to Fig. 17 for legend.
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Paragraph 16 YANMAR
torque. Screws (C) should be tightened
to 12-16 N-m (106-142 ft.-lbs.) torque.
Screws attaching spindle (26) to gear
housing (15) should be tightened to 45-58
N-m (33.19-42.78 ft.-lbs.) torque. Wheel
retaining lug bolts should be tightened
to 79-97 N-m (58.27-71.54 ft.-lbs.) tor-
que. The front axle should contain 3
liters (3.2 quarts) of gear lubricant.
DIFFERENTIAL
AND BEVEL GEARS
YM135D and YM155D Models
16. R&R AND OVERHAUL. Re-
move the axle assembly from tractor as
outlined in paragraph 5. Support axle
securely, then unbolt right axle housing
(99-Fig. 17) from center housing (57),
then remove differential. Left axle hous-
ing can be unbolted and separated from
center housing if desired. Unbolt and
remove pinion and carrier (62) from
center housing.
NOTE: Shims (58) adjust pinion mesh
position with ring gear. Shims (44 and 100)
Fig. IT—Exptaded ¥i0w of the complete axle housing used on late YM1350 and YMiSSD models. Early models are similar.
10.
Fasteners attaching
outer drive I 'msing
Nut attaching steering
arm
tScrews attaching axle
housing cover
Fill plug
Pivot pin
Stop screw
Axle and hub
Washer (30x42x2 mnn)
Wear sleeve
Cover
Snap ring
Oil seal
Gasket
Bearings (6306 for late
models)
Spacer (30x38x13.5 nun
for late models)
Spacer (30.5x45x9.5 mm
for late models) and
shims
11. Bevel gear
15. Gear housing
17. Seal
18. Bevel gears
19. Ball bearing (6205
lower, 6205U upper)
20. Gasket
21. Spacer (25x30x72.67
mm)
22. Tie rod arm
23. Washer (25.5x60x1.6
mm)
24. Roller bearings
(28x33x16 mm early;
25x31x20 mni late)
25. Spindle housing
26. Spindle
27. Oil seal
28. Thrust bearings (51105)
29. Washers (22.5x40x1
mm)
30. Washer
34. Shims
35. Steering arm
36. Drive gear
37. Drive axle
39. Washer (25.5x32x1 mm)
and shims
40. Snap ring
41. Gasket
42. Axle housing
44. Shim (same as 100)
45. Carrier bearing (6207)
47. Bearing (6305)
49. Gasket
56. Thrust washer (same as
70)
57. Center housing
58. Shims
59. Drive pinion
60. Bearing (6305)
61. "O"ring
62. Pinion housing
63. Bearing (6304)
64. Snap rings
65. "0" ring
66. Universal flange
67. OU seal
68. Lock plate
69. Screw
70. Thrust washer (same as
56)
72. Pivot bushings
91. Thrust washer (14 or
15 mm)
92. Ring gear
93. Thrust washer (0.9, 1.0,
1.1 and 1.2 mm thick)
94. Side gear
95. Thrust washer (0.76-0.86
mm thick)
96. Pinions
97. Pinion shaft
98. Differential housing
99. Axle housing
100. Shims (same as 44)
101. Roll pin
8

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Yanmar ym240 tractor service repair manual

  • 1. SHOP MANUAL YANMARModels YM135, YM135D, YM155, YM155D, YM195, YM195D, YM240, YM240D, YM330 and YM330D Tractor serial number is stamped on left side of clutch housing on transmission hous- ing. Engine model and serial number is located on a data plate attached to right side of engine for YM135, YM135D, YM155 and YM155D models. Engine model and serial number is located on a data plate attached to left side of engine for YM195, YM195D, YM240, YM240D, YM330 and YM330D models. i INDEX (By Starting Paragraph) YM135, YM135D BRAKES 210 CLUTCH 130 COOLING SYSTEM 115 DIESEL FUEL SYSTEM raters & Bleeding 85 Nozzles 90 Thermostart 97 Timing 86 DIFFERENTIAL Front 16 Rear 185 ELECTRICAL SYSTEM Alternator & Regulator 120 Starter 125 ENGINE Camshaft 60 Connecting Rods 71 Crankshaft 72 Cylinder Head 45 Flywheel 78 Oil Pump 80 Pistons & Rings 66 Remove & Reinstall 42 Tappet Adjustment 47 Timing Gears 56 Valves & Seats 48 FINAL DRIVE Front 15 Rear 200 FRONT AXLE Four Wheel Drive 4 Two Wheel Drive 1 FRONT WHEEL DRIVE 15 GOVERNOR 101 HYDRAULIC SYSTEM 240 POWER TAKE OFF 215 STEERING GEAR 10 TRANSMISSION 150 This service manual provides specifications in both the Metric (SI) and U.S. Customary systems of measurement. The first specification is given in the measuring system used during manufacture, while the second specification (given in parenthesis) is the converted measurement. For instance, a specification of "0.28 mm (0.011 inch)" would indicate that the equipment was manufactured using the metric system of measurement and the U.S. equivalent of 0.28 mm is 0.011 inch. YM155, YM155D 210 130 115 85 90 97 86 16 185 120 125 60 71 72 45 78 80 66 42 47 56 48 15 200 4 1 15 101 240 215 10 150 YM195, YM195D 210 130 115 85 90 97 88 21 190 121 125 61 71 72 45 78 80 66 42 47 57 48 20 202 4 1 20 103 240 220 10 160 YM240, YM240D 210 130 115 85 90 97 88 21 190 121 125 61 71 72 45 78 80 66 42 47 57 48 20 202 4 1 20 103 240 220 10 160 YM330, YM330D 210 130 115 85 90 97 88 31 195 121 125 61 71 73 45 78 80 66 42 47 57 48 30 204 4 1 80 103 240 230 10 170
  • 2. SHOP MANUAL Paragraphs 1-3 CONDENSED SERVICE DATA YM135, YM155, YM195, YM240, YM330, GENERAL YM135D YM155D YM195D YM240D YM330D Engine Make OWN Engine Model 2T73A 2TR13A 2T84A 2TR20A-X 3T84A or 3T84A-LP Number of Cylinders 2 2 2 2 3 Bore-mm (in.) 73(2.87) 75(2.95) 84(3.31) 90(3.54) 84(3.31) Stroke-mm (in.) 75(2.95) 75(2.95) 90(3.54) 90(3.54) 90(3.54) Displacement-cc 627 662 997 1145 1496 Cubic Inches 38.26 40.39 60.84 69.87 91.29 Transmission - Speeds Forward 6 6 8 8 8 Speeds Reverse 2 2 2 2 2 TUNE-UP FiringOrder 1-2 1-2 1-2 1-2 1-3-2 Number 1 Cyl. Rear Valve Tappet Gap-Cold Exhaust-mm (in.) 0.2(0.008) 0.2(0.008) 0.15(0.006) 0.15(0.006) 0.15(0.006) Inlet-mm (in.) 0.2(0.008) 0.2(0.008) 0.15(0.006) 0.15(0.006) 0.15(0.006) Horsepower at pto ... ... ... 19.8 Battery-Volts 12 12 12 12 12 Polarity Ground Neg. Neg. Neg. Neg. Neg. CAPACITIES-All capacities are in liters and (quarts). Cooling System 3.2(3.4) 3.2(3.4) 4.6(4.9) 4.6(4.9) 6.2(6.5) Engine Crankcase 2.2(2.3) 2.4(2.5) 4.0(4.2) 4.0(4.2) 6.4(6.8) Front Drive Axle 3.0(3.2) 3.0(3.2) 5.0(5.3) 6.0(6.3) 7.0(7.4) Fuel Tank 9.5(10) 15(15.8) 22(23.2) 22(23.2) 32(33.8) Transmission, Hydraulic System and Rear Axle- Two Wheel Drive 9.5(10) 9.5(10) 15(15.8) 15(15.8) 20(21) Four Wheel Drive 9(9.5) 9(9.5) 15(15.8) 15(15.8) 20(21) FRONT AXLE AND STEERING GEAR FRONT AXLE ASSEMBLY Two Wheel Drive Models 1. ADJUSTMENT. Refer to ap- propriate Fig. 1, 2, 2A or 3 for exploded view of fixed or adjustable tread non- driving axle. Toe-in should be 4-8 mm (5/32-5/16 in.) for all models. Length of drag link should be adjusted to provide equally sharp turns in both directions. Front axle should not have excessive front to rear clearance at pivot shaft (5). Excessive clearance can be removed from YM195 and YM240 models by relocating brackets (29-Fig. 2) closer ^together. Be sure all attaching screws Fare retightened after adjustment is com- plete. On all other models, adjust axle play at pivot by tightening the castle nut (2- Fig. 1 or 3) on pivot shaft. Be sure to install cotter pin to prevent nut from loosening after adjustment is complete. Front wheel bearings should be removed, cleaned, inspected and renew- ed if damaged or repacked with new grease after each 300 hours of opera- tion. Tighten the hub retaining castle nut, then lock position by installing cot- ter pin. Tighten wheel lug bolts to 78-98 N-m (57.5-72.3 ft.-lbs.) torque. 2. REMOVE AND REINSTALL. Support front of tractor and disconnect drag link from steering arm. On YM135 and YM155 models, remove cotter pin and castle nut (2 - Fig. 1) from axle pivot shaft, support axle with jack, then remove washer (3) and pivot shaft (5). On YM195 and YM240 models, support axle with jack, unbolt pivot brackets (29-Fig. 2 or 2A) from frame, then lower axle. On YM330 models, support axle with jack, remove cotter pin from castle nut at rear of pivot shaft, then loosen castle nut (2-Fig. 3). Remove self locking nut (39), washer (38), sleeve (37) and snap ring (36), then withdraw the pivot shaft. When assembling YM135 model, cas- tle nut (2-Fig. 1) should be toward rear. On YM155 model, castle nut is toward front. Bushings (4) are 25 mm (0.984 in.) long for YM135 models; 24 mm (0.945 in.) long for YM155 models. Tighten cas- tle nut (2) on YM135 and YM155 models enough to remove all axle play; however, axle should move smoothly and freely on pivot. 3. OVERHAUL. The steering spindle (18-Fig. 1, 2, 2A and 3) is equipped with renewable bushings (13) and some
  • 3. Paragraph 3 Cont. YANMAR models are equipped with bearings (15 and 33). Inside diameter of bushings (13) should be sufficient to provide correct clearance for the spindle. Adjust spindle end play by adding covers (11-Fig. 1, 2 or 2A) or shims (40-Fig. 3) as required. YM135, YM155 Spindle diameter at bushing 24.948-25.0 mm (0.9822-0.9843 in.) Spindle to bushing clearance, Desired 0.020-0.124 mm (0.0008-0.0049 in.) Wear limit 0.4 mm (0.0157 in.) Spindle end play, Desired 0.02-0.086 mm (0.0008-0.0011 in.) Wear limit 1.0 mm (0.0394 in.) Center pivot pin diameter 21.947-21.980 mm (0.8641-0.8654 in.) Center pivot to bushing clearance. Desired 0.040-0.123 mm (0.00157-0.0048 in.) Wear limit 0.4 mm (0.0157 in.) Axle end play on center pin 0.0-0.5 mm (0-0.0197 in.) YM195, YM240 Spindle diameter at bushing 24.948-25.0 mm (0.9822-0.9843 in.) Spindle to bushing clearance. Desired 0.020-0.122 mm (0.0008-0.0049 in.) Wear limit 0.25 mm (0.0098 in.) Spindle end play, Desired 0.02-0.86 mm (0.0008-0.0011 in.) Wear limit 1.0 mm (0.0394 in.) Center pivot pin diameter 24.967-25.0 mm (0.9830-0.9843 in.) Center pivot to bushing clearance, Desired 0.020-0.105 mm^ (0.0008-0.0041 in.) Wear limit 0.4 mm (0.0157 in.) Axle end play on center pin, Desired 0.1-0.3 mm (0.004-0.011 in.) Maximum limit 0.5 mm (0.0197 in.) YM330 Spindle diameter at bushing 29.959-29.980 mm (1.17354.1803 in.) Spindle to bushing clearance, Desired 0.020-0.074 mm (0.0008-0.0029 in.) Wear limit 0.25 mm (0.0098 in.) Spindle end play. Desired .0.02-0.6 mm (0.0008-0.0236 in.) Wear limit 0.7 mm (0.0276 in.) Fig. 1 - Exploded vtew of non-adfustabte front ax/e used on YM155 models. Axle used on YM135 Is similar. Fig. 2—Exploded view of standard non- adiustable front axle used on some YM195 and YM240 models. Refer to Fig. 1 for wbeel bub and bearings. Refer to Fig. 2A for optional adjustable axle and beavy duty axle. 1. Cotter pin 2. Castle nut 3. Washer 4. Bushings (25x24 mm for YM135, 25x25 mm for YM155) 5. Pivot shaft 6. Frame 7. Nut 8. Lockwasher 9. Plain washer 10. Steering arm 11. Cover washer (40x3 mm) 12. "0" ring 13. Bushing (29x38 mm) 14. Axle main member 15. Ball bearing (6205) 16. Snap ring 17. Seal 18. Spindle 19. Seal 20. Snap ring 21. Ball bearing (6205) 22. Hub 23. Ball bearing (6204) 24. Plain washer 25. Castle nut 26. Cotter pin 27. Cap 28. Tie rod assy. 1. Cotter pin 2. Castle nut 3. Washer 4. Bushings (25x25 mm) 6. Frame 7. Nut 8. Lockwasher 9. Plain washer 10. Steering wrm 11. Cover 12. "O" ring 13. Bushing (29x38 mm) 14. Axle main member 1 15. Ball bearing (6205) 16. Washer (42x51.8x1 mm) 17. Seal 18. Spindle 28. Tie rod 29. Pivot bracket
  • 4. SHOP MANUAL Paragraphs 4-11 Center pivot pin diameter 34.95-34.975 mm (1.3760-1.3770 in.) ^Center pivot to bushing clearance. Desired 0.025-0.089 mm (0.0010-0.0035 in.) Wear limit 0.4 mm (0.0157 in.) Axle end play on center pin. Desired 0.1-0.3 mm (0.0039-0.0118 in.) Maximum limit 0.5 mm (0.0197 in.) Four Wheel Drive 4. ADJUSTMENT. Refer to ap- propriate paragraphs 15 through 31 for service to individual units. Toe-in should be 4-8 mm for all models. 5. REMOVE AND REINSTALL. To remove the front axle from four wheel drive models, first block rear wheels. Loosen the drive shaft cover clamps, remove retaining screws, then move drive shaft cover out of the way. Detach drive shaft from front axle drive pinion. On all models except YM135D and YM155D models, be careful not to lose the steel balls from drive shaft collars. On all models, detach drag link from steering arm. Support weight of tractor by attaching overhead hoist to front weight support, then remove both front wheels. Place a jack under center of front axle to support axle securely when attaching screws are removed. On all models, except YM330D, remove castle nut from axle pivot, then withdraw pivot shaft. Be careful to pre- vent axle from falling when pivot is Fig, 2A-Exploded vfew of adfustabtB axle awalfable for YMIBS and YfAZAO models. Except for ad- lustable width feature, heavy duty non-adjustable axle is similar. 26. Cotter pin 27. Cap 29. Pivot bracket 30. Shim 31. Axle extension 32. Axle center member 33. Thrust bearing (51106) 4. Bushings (30x40 mm) 6. Frame 10. Steering arm 11. Cover 12. "0" ring 13. Bushing 17. Seal 18. Spindle 19. Seal 21. Taper bearing (32007) 22. Hub 23. Taper bearing (30205) 24. Plain washer 25. Castle nut removed, then lower axle away from tractor. On YM330D models, disconnect bat- tery cables, then remove battery. Remove locknuts (N-Fig. 4) from screws which attach front axle pivot brackets to frame. Remove all eight screws which attach axle pivot brackets to frame, then lower axle away from tractor. When installing, reverse removal pro- cedure. Be especially careful to prevent axle from slipping from jack while at- taching center pivot. On all models except YM330D, locate axle in correct position, then install center pivot pin. Nut should be toward rear for YM135D models, toward front for YM155D models. Tighten castle nut on YM135D and YM155D models enough to remove all end play, but be sure that axle pivots freely. Install cot- ter pin through castle nut to maintain adjustment. On YM195D and YM240D models, shims (54-Fig. 23) should be added to provide axle with less than 0.6 mm (0.0236 in.) end play. Axle must be free to move and not bind. Coat threads of the four screws which retain pivot pin with locking compound after selecting correct thickness of shims. On YM330D models, coat threads of screws which retain axle pivot brackets with a locking compound and tighten to 149 N-m (109.9 ft.-lbs.) torque. End play of axle in center pivot brackets is ad- justed by changing thickness of thrust spacers (54-Fig. 23). End play should be less than 0.6 mm (0.0236 in.), but should not cause binding. Thrust spacers (54) are available in 2.0, 2.3 and 2.6 mm thicknesses. STEERiNG GEAR All Models 10. REMOVE AND REINSTALL. Remove cap from center of steering wheel, remove steering wheel retaining nut, then use puller to remove steer- ing wheel shaft. Disconnect battery ground cable from battery. Remove the battery from YM135 models. On all models remove the instrument panel and the fuel tank. Detach drag link from steering arm, then unbolt, and remove the steering gear assembly. Reinstall steering gear, reversing the removal procedure. Coat threads of at- taching screws with sealer before in- stalling. 11. OVERHAUL. Remove cap screws attaching side cover (16-Fig. 5 or Fig. 6) to housing (21), remove locknut (14), then turn adjusting screw (15) in to push cover away from housing. Loosen nut (25) and turn shaft (6) until gear on shaft (19) is aligned with opening in
  • 5. Paragraph 11 Cont. YANMAR housing. Remove adjusting screw (15), then bump end of shaft (19) out toward right. After steering arm (24) is released from end of shaft, remove nut (25) and steering arm, then withdraw shaft (19) from housing. Unbolt steering column (12), then withdraw shaft (6) and ball nut (8). Bushings (22) are available only as an assembly with housing (21). Seal (23) should be flush with housing. Inner race for ball bearings (7) is integral with shaft (6) and disassembly is not recommended. Clean ball nut (8) without disassembling and check for smoothness. Ball nut is available only as an assembly with shaft (6). Apply grease liberally to shaft and ball nut. Grease lower bearing (7) and position in bearing race located in hous- ing. Grease upper bearing (7) and locate on shaft (6). Position shaft (6) with ball nut (8) and upper bearing in housing (21). Position column (12) over shaft and select thickness of shims (13) which will permit free movement of shaft in bear- ings (7) with no end play of shaft. Install column (12) with sealing "0" ring (9) after selecting correct thickness of shims (13). Turn shaft (6) until ball nut (8) is in center of travel. Coat cross shaft (19) with grease, then install with center tooth in center valley of ball nut. Posi- tion adjustment screw (15) and shim (18) in end of shaft and gasket (20) on hous- ing, then install cover (16). Turn ad- justing screw (15) out through cover (16) while installing, then tighten the cover attaching screws to 23-30 N-m (16.96-22.13 ft.-lbs.) torque. Be sure that adjusting screw (15) remains loose while tightening the cover attaching screws. Install steering arm (24) over shaft splines with index marks aligned. Some models have a missing spline to assist alignment of steering arm. Adjust screw (15) to provide 30-50 mm (1 3/16-2 in.) free play at rim of steering wheel, then lock adjustment with nut (4). Initial ad- justment can be accomplished by turn- ing screw clockwise as far as possible, then backing screw up V4-turn and lock with nut (14). Wear is indicated if play at rim exceeds 50 mm (2 in.) with correct adjustment of screw (15) and correct thickness of shims (13). Steering gear should be filled with SAE 90 gear lubricant. Capacity is 20 mL for YM135, YM135D, YM155 and YM155D. Capacity is 26 mL for other models. Fig. $- Exploded view of adfustable axle used on rM330 models. 1. Cotter pin 2. Castle nut 3. Washer 4. Bushings 5. Pivot pin 6. Frame 10. Steering arm 11. Cover 12. "0" ring 13. Bushings 17. Seal 18. Spindle 19. Seal 21. RoUer bearing (32007) 22. Hub 23. Roller bearing (30205) 24. Plain washer 25. Castle nut 26. Cotter pin 27. Cap 30. Shims 31. Axle extension 32. Axle center member 33. Thrust bearing 34. Plain washer 35. Seal 36. Snap ring 37. Taper sleeve 38. Washer 39. Nut 40. Shims Fig. 4 "View of nuts {Hi used to iock tbe screws tbat attacb front drive axle brackets to frame of yM330O modeis. Nuts are located under battery bracket Fig. 5 — Expioded view of steering gear typlcai of type used on YM135, YM135D, rM155 and YM155D models. P. Plug 2. Nut 3. Washer 6. Steering shaft 7. Bearings 8. Ball nut 9. "0" ring 11. Bushing 12. Column 13. Shims 14. Locknut 15. Adjusting screw 16. Side cover 17. Bushing 18. Shim 19. Sector gear and cross shaft 20. Gasket 21. Housing 22. Bushing 23. Seal 24. Steering arm 25. Nut 10 ^ 25 Fig. 6—Exploded view of steering gear typical ol type used on YM195, YM195D, YM240, YM240D, YM330 and YM330D modeis. Refer to Fig. 5 for iegend.
  • 6. SHOP MANUAL FRONT WHEEL DRIVE OUTER DRIVE HOUSING YM135D and YM155D Models 15. R&R AND OVERHAUL. The complete outer drive housing can be separated from axle after removing fasteners (A-Fig, 15) or disassembly can be accomplished before detaching outer end of axle from center section. To remove the complete outer drive housing, remove wheel, detach drag link and/or tie rod from steering arm and support axle from tipping. Support outer drive housing separately, then remove the two screws and two nuts (A). Move outer drive housing away from ax- le center section. Disassembly of outer drive assembly can be accomplished as outlined in the following paragraphs. Some disassembly can be accomplish- ed with outer drive housing attached to axle center section. If attached, remove wheel and support axle from tipping. Remove the four screws (C-Fig. 16), then withdraw the axle (1) and cover (4) from gear housing (15). Be sure to save shims (7) located between cover and housing. Inner bearing (8), spacer (9) and snap ring (5) must be removed before with- drawing outer bearing (8) and seal (6) from around axle (1). Seal wear sleeve (3) can remain on axle unless new sleeve is to be installed. Support outer drive housing and remove nut (B), washers, shims (34) and steering arm (35). Unbolt spindle hous- ing (25) from gear housing (15) and separate the two housings. Gear (18) and bearings (24 and 28) can be removed, cleaned and inspected. Bearings (19) and spacer (21) can be pressed from housing (25) if removal is required. When assembling, upper bearing (19) is sealed on one side and is identified by "6305U" marked on side of bearing. The one sealed side should be down, away from seal (27), for the uppermost bear- ing: (19). The lower bearing marked "6305", not sealed and should be in- stalled in lower bearing bore. Spring loaded lip of seal (27) should be down toward bearing; spring loaded lip of seal (17) should be up. Inside diameter of one race for thrust bearings (28) is 25 mm, the other race inside diameter is 25.2 mm. Install thrust bearings with large I.D. inner races toward gear (18). Re- mainder of assembly is reverse of disassembly; however, shims should be used to adjust backlash between gears. Vary the thickness of shims and washer at (89) to obtain 0.1-0.3 mm (0.0039-0.0118 in.) backlash between Paragraph 15 99 Fig, 15-Crosss0ctlon of front drive axie used on late rMY35D and YM1SSD models. Early models are similar. Refer to Fig, 17 tor legend. gears (18 and 36). Vary thickness of shims at (10) to obtain 0.1-0.3 mm (0.0039-0.0118 in.) backlash between gears (11 and 18). Shims (34) should be installed between washers (29) as necessary to limit the clearance between bottom of flat washer and the top of up- per washer (29) to less than 0.1 mm (0.0039 in.). Do not reduce clearance to less than zero which would cause the steering to bind. Turn stop screw (S) as required so that rear surface of head is 11 mm from rear surface of flange, then tighten locknut against front surface. Screws and nuts (A) should be tighten- ed to 45-58 N-m (33.19-42.78 ft.-lbs.) Fig. 16—Exploded view of outer drive housing used on late YM135D and YMiSSD models. Early models are similar, inner bearing (8) Is S305 on early models. Refer to Fig. 17 for legend.
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  • 8. Paragraph 16 YANMAR torque. Screws (C) should be tightened to 12-16 N-m (106-142 ft.-lbs.) torque. Screws attaching spindle (26) to gear housing (15) should be tightened to 45-58 N-m (33.19-42.78 ft.-lbs.) torque. Wheel retaining lug bolts should be tightened to 79-97 N-m (58.27-71.54 ft.-lbs.) tor- que. The front axle should contain 3 liters (3.2 quarts) of gear lubricant. DIFFERENTIAL AND BEVEL GEARS YM135D and YM155D Models 16. R&R AND OVERHAUL. Re- move the axle assembly from tractor as outlined in paragraph 5. Support axle securely, then unbolt right axle housing (99-Fig. 17) from center housing (57), then remove differential. Left axle hous- ing can be unbolted and separated from center housing if desired. Unbolt and remove pinion and carrier (62) from center housing. NOTE: Shims (58) adjust pinion mesh position with ring gear. Shims (44 and 100) Fig. IT—Exptaded ¥i0w of the complete axle housing used on late YM1350 and YMiSSD models. Early models are similar. 10. Fasteners attaching outer drive I 'msing Nut attaching steering arm tScrews attaching axle housing cover Fill plug Pivot pin Stop screw Axle and hub Washer (30x42x2 mnn) Wear sleeve Cover Snap ring Oil seal Gasket Bearings (6306 for late models) Spacer (30x38x13.5 nun for late models) Spacer (30.5x45x9.5 mm for late models) and shims 11. Bevel gear 15. Gear housing 17. Seal 18. Bevel gears 19. Ball bearing (6205 lower, 6205U upper) 20. Gasket 21. Spacer (25x30x72.67 mm) 22. Tie rod arm 23. Washer (25.5x60x1.6 mm) 24. Roller bearings (28x33x16 mm early; 25x31x20 mni late) 25. Spindle housing 26. Spindle 27. Oil seal 28. Thrust bearings (51105) 29. Washers (22.5x40x1 mm) 30. Washer 34. Shims 35. Steering arm 36. Drive gear 37. Drive axle 39. Washer (25.5x32x1 mm) and shims 40. Snap ring 41. Gasket 42. Axle housing 44. Shim (same as 100) 45. Carrier bearing (6207) 47. Bearing (6305) 49. Gasket 56. Thrust washer (same as 70) 57. Center housing 58. Shims 59. Drive pinion 60. Bearing (6305) 61. "O"ring 62. Pinion housing 63. Bearing (6304) 64. Snap rings 65. "0" ring 66. Universal flange 67. OU seal 68. Lock plate 69. Screw 70. Thrust washer (same as 56) 72. Pivot bushings 91. Thrust washer (14 or 15 mm) 92. Ring gear 93. Thrust washer (0.9, 1.0, 1.1 and 1.2 mm thick) 94. Side gear 95. Thrust washer (0.76-0.86 mm thick) 96. Pinions 97. Pinion shaft 98. Differential housing 99. Axle housing 100. Shims (same as 44) 101. Roll pin 8