Yanmar YM135 YM135D YM155 YM155D YM195 YM195D YM240 YM240D YM330 YM330D Tractor Workshop Service Repair Shop Manual

SHOP MANUAL YANMAR Models YM135, YM135D, YM155, YM155D, YM195, YM195D, YM240, YM240D, YM330 and YM330D Tractor serial number is stamped on left side of clutch housing on transmission housing. 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 complete. 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 cotter 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, castle 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 castle 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 prevent 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 battery 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 procedure. Be especially careful to prevent axle from slipping from jack while attaching 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 cotter 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 adjusted 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 steering 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 attaching screws with sealer before installing. 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 housing. 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 bearings (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 housing, then install cover (16). Turn adjusting 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 adjustment can be accomplished by turning 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 axle center section. Disassembly of outer drive assembly can be accomplished as outlined in the following paragraphs. Some disassembly can be accomplished 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 housing (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 bearing: (19). The lower bearing marked "6305", not sealed and should be installed 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 upper 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 tightened 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.

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.) torque. 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 housing 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

SHOP MANUAL Paragraph 20 adjust carrier bearings (45). Moving shims (44 and 100) from one side to the other moves the differentiai and therefore ad- justs bevei gear backiash. Be carefui not to iose or damage shims when dis- assembiing. The pinion bearings (60 and 63), carrier (62) and related parts can be assembled on the pinion shaft (59) before assembling into center housing. The mesh position can be checked using a mandrel manufactured to the dimen- sions shown in Fig. 18. Distance (A) should be 15.95-16.05 mm (0.6280- 0.6319 in.) if checked with mandrel. If mandrel is not available and thickness of shims (58-Fig. 17) is not correct, mesh position can be checked by coating teeth of ring gear with mechanics blueing, then installing differential in center Fig. 18—A mandrel can be used to determine correct t/ifc/rness of sbims (58) to In- staii, by measuring distance iA}. Diameter of mandrei at (B) sbouid be 71.9972.00 mm, length at (C) sliouid be 60 mm and radius (D) of boit cirde sbouid be 58 mm. housing (57) with left carrier bearing (45) and axle housing (42) installed. The toe of the pinion gear should be aligned with center edge of ring gear teeth and mesh pattern should be approximately centered on teeth. Change thickness of shims (58) to set correct pinion position. Change the thickness of shims (44) under left carrier bearing to provide 0.1-0.3 mm (0.0039-0.0118 in.) backlash between pinion and ring gear teeth. Be sure that left axle housing is securely attached to the center housing and that differential and left carrier bearing are firmly seated when measuring backlash. Shims should be provided at (100) to remove all play from carrier bearings, but should not cause bearings to bind when axle housing is assembled. Screws attaching left axle housing (42) to center housing (57) should be tightened to 38 36 B 28 B 59 Fig. 20 - Cross section of front drive axle used on YM195D modeis. The wheei dxle (U S^^r (11) and related parts are different than used on YM240D models shovi/n in Fig. 21. Refer to Fig. 22 for legend. 44.7-58.3 N-m (33-43 ft.-lbs.) torque. Screws attaching pinion housing (62) to center housing (57) should be tightened to 12.2-16.3 N-m (108-144 in.lbs.) torque. Screw (69) should be tightened to 23.0-29.8 N-m (203.6-263.8 in.-lbs.) torque, then locked with plate (68). Screws attaching right axle housing (99) to center housing (57) should be tightened to 23.0-29.8 N-m (203.6-263.8 in.-lbs.) torque. OUTER DRIVE HOUSING YM195D and YM240D Models 20. R&R AND OVERHAUL. The complete outer drive housing can be separated from axle after removing fasteners (A-Fig. 20 or 21) 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 eight screws (A). Move the outer drive housing away from axle center section. The axle will be with- drawn from differential side gears at center. Disassembly of outer drive assembly can be accomplished as outlined in the following paragraphs. Some disassembly can be accomplished with outer drive housing attached to axle center section. If attached, remove wheel and support axle from tipping. Remove the six screws (C-Fig. 22), then withdraw the axle (1) and cover (4) from housing (15). Bend tab of lockwasher (13) out of slot in nut (14), then remove nut and washer. Press axle (1) out of gear (11) and bearings (8 and 12). Bearing (12) is retained on hub of gear (11) by snap ring (5) of YM240D models. Wear sleeve (3) and "0" ring (2) are used only on YM240D models. Support outer drive housing, then remove nut and screws (B). Housing (15) can be separated from housing (25) after screws are removed. Remove steering arm (35) and drive key. Remove snap ring (30), then withdraw gear (18), bearing (29), gear (28) and snap ring (27). Be careful not to damage bearings (24) and shims (34). Inspect the needle bearing (24), the races of shaft (26) and gear (18) for damage. Backlash between gears (28 and 36) should be 0.1-0.15 mm (0.0039-0.0059 in.) with maximum limit of 0.5 mm (0.0197 in.). Adjust backlash of gears (28 and 36) by changing thickness of shims at (37) between washer (39) and bearing (38). Be sure gear (28) and bearing (29) 9

Paragraphs 21-30 YANMAR 38 36 B 28 B 59 69 Fig, 21 - Cross-section of front drive axle used on fM240D models. Refer to Fig. 20 for cross-section of axle used on YM195D models and to Fig, 22 for exploded view of YM240D axle. are seated firmly against snap ring (30) and that gear (36), bearing (38), shims (37) and washer (39) are firmly seated against snap ring (40) before measuring backlash. Backlash between gears (11 and 18) should be 0.1-0.15 mm (0.0039-0.0059 in.) with maximum limit of 0.5 mm (0.0197 in.). Adjust backlash of gears (11 and 18) by changing thickness of shims at (7). Be sure gears and bearings are firmly seated before checking backlash. DIFFERENTIAL AND BEVEL GEARS YM195D and YM240D Models 21. R&R AND OVERHAUL. Re move the axle assembly from tractor as outlined in paragraph 5. Support axle securely, then unbolt the left axle housing (42-Fig. 23) from the center housing (57), then remove the differential. Right axle housing can also 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) adjust carrier bearings (45). Moving shims (44 and 100) from one side to the other moves the differentiai and therefore ad- justs bevel gear bacidash. Be careful not to lose or damage shims when disassembling. The pinion (59), bearings (60) and related parts should be assembled in carrier (62). Adjust taper bearings (60) by tightening nut (69). When bearings are properly adjusted, 0.3145-1.5700 N-m (3-14 in.-lbs.) torque will be required to start turning the pinion. The mesh position can be checked by coating teeth of ring gear with mechanics blueing, then installing differential in center housing (57) with right carrier bearing (45) and axle housing (99) installed. The toe of the pinion gear should be aligned with center edge of ring gear teeth and mesh pattern should be approximately centered on teeth. Change thickness of shims (58) to set correct pinion position. Change the thickness of shims (100) under right carrier bearing to provide 0.17-0.23 mm (0.0067-0.0091 in.) backlash between pinion and ring gear teeth. Be sure that right axle housing is securely attached to the center housing and that differential and right carrier bearing are firmly seated when measuring backlash. Shims should be provided at (44) to remove all play from carrier bearings, but should not cause bearings to bind when axle housing is assembled. OUTER DRIVE HOUSING YM330D Models 30. R&R AND OVERHAUL. The complete outer drive housing can be separated from axle after removing screws (A-Fig. 30) 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 housing to prevent tipping. Support outer drive housing separately, then remove screws (A). Move outer drive housing off dowel pins away from axle center section. Disassembly of outer drive assembly can be accomplished as outlined in the following paragraphs. Disassembly can be accomplished with outer drive housing attached to or separated from axle center section. If attached, remove wheel and support axle from tipping. Remove the eight screws (C-Fig. 31), then use two of the screws in threaded jack screw holes (J) to push cover (4-Fig. 32) away fromi gear housing (15). Be sure to save shims" (7) and record thickness, which should be the same at all locations. Bend tang washers (13) out of notch in 10

SHOP MANUAL Paragraph 30 Cont. nut (14), then remove nut and tang washer. Bump axle (1) out of bearing (12) and gear (11). Seal wear sleeve (3) will remain on axle (1). Unbolt bearing [retainer plate (10), then use a soft drift to drive gear and bearing (8) from cover (4). Support outer drive housing, then remove four screws (B-Fig. 31). Sep- arate outer drive housing (15-Fig. 32) from spindle housing (25). Be careful to save and record thickness of shims (34) located between steering arm (35) and outer drive housing (15). Steering arm (35) can be lifted from axle. Unbolt spindle upper cap (31), then bump spindle shaft (26), spindle cap (31), gear (28) and bearing (29), UP out of housing (25). Bevel gear (36), bearing (37), thrust washer (39) and shims (38) can be removed after removing snap ring (40). If not already removed, remove screws (A-Fig. 30) and lift housing from axle housing. Clean and check all parts, especially seals, bearings and journals for roller bearing. Renew all seals and "0" rings upon reassembly. Thickness of shims (7 and 38-Fig. 32) is used to adjust backlash between gears; shims (34) are used to adjust spindle end play. Refer to the following for selection of shims and reassembly. Install bearing (24) and snap ring (23) in lower bore of housing (25), Assemble spindle (26), snap ring (27), gear (28) and bearing (29), then locate in spindle housing (25). Install gasket (30) and cap (31). Tighten cap retaining screws to 23-30 N-m (16.96-22.13 ft.-lbs.) torque. Install gear (36) and bearing (37) in bore of housing (25). Bump bearing into bore as far as possible, then install thrust washer (39) and snap ring (40). Measure gap between bearing and thrust washer with feeler gage, then install shims (38) necessary to reduce clearance to 0.07-0.17mm (0.0028- 0.0067 in.). Actual backlash between teeth of gears (28 and 36) should be 0.10-0.15 mm (0.0039-0.0059 in.). Remove snap ring (40) and thrust washer (39) to install shims, then reinstall thrust washer and snap ring. Measure clearance again after shims are installed. Be sure that open section of snap ring is alig^ned with notch at bottom of housing to assure proper luhri- cation. 22 1. Axle 2. "0" ring (YM240D only) 3. Wear sleeve (40x50x20 mm, YM240D only) 4. Cover 5. Snap ring (YM240D only) 6. Oil seal 7. Shims 8. Ball bearing (6007 for YM195D, 6008 for YM240D) 9. Gasket 10. Snap rings (1 used on YM195D) 11. Bevel gear 12. Ball bearing (6211 for YM240D) 13. Lockwasher 14. Nut 15. Gear housing 16. Seal 17. Seal 18. Bevel gear 19. Washer (25x35x2 mm) 20. Spacer (28x33.5x18 mm for YM195D, 28x33.5x22.5 mm for YM240D) 21. Washer (28x33x6.5 mm for YM195D, 28x33.5x2 mm for YM240D) 22. Tie rod arm 23. Snap ring 24. Roller bearings (K283518) 25. Spindle houBing 26. Spindle shaft 27. Snap ring 28. Bevel gear 29. Ball bearing (6013) 30. Snap ring 31. Spacer (42.7x25.5 mm for YM195D, 48.6x38.5 mm for YM240D) 32. Ball bearing 34. Shims 35. Steering arm 36. Drive gear 37. Shims 38. Ball bearing (6207) 39. Washer 40. Snap ring 41. "0" ring 42. Axle housing 46. Snap rings 47. Drive axle Fig. 22-Exploded view of outer drive housing used on YM240D models. Model YM195D Is simitar except for differences in axle (1), gear (11) and related parts. 11

Yanmar YM135 YM135D YM155 YM155D YM195 YM195D YM240 YM240D YM330 YM330D Tractor Workshop Service Repair Shop Manual

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