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Paragraph 40

YANMAR
B. Screws
C. Screws
1. Axle
2. "0" rinff
3. Wear sleeve
4. Cover
5. Outer seal
6. Inner seal
7. Shims
8. Ball bearing (6211)
9. "0" ring
10. Retainer
11. Gear
12. Roller bearing
(NJ207)
13. Lockwasher
14. Nut
15. Gear hotting
16. Upper seal
Crc6) C)
17. Lower seal
C)
18. Bevel gear
19. BaU bearing (6209)
20. Gasket
21. Ck)ver
22. lie rod arm
23. Snap ring
24. Needle bearing
(HMK3530)
25. Spindle housing
26. Spindle shaft
27. Snap ring
28. Bevel gear
28A. Washer (30.5x60
mm)
29. BaU bearing
(6306UU)
30. Gasket
31. Cap
32. Bushing (35x39x20
mm)
33. "0" ring
34. Shims
35. Steering arm
36. Bevel gear
37. Ball bearing (6209)
38. Shims
39. Washer (85x1 mm)
40. Snap ring
41. "0" ring
Fig. 32-Exploded wiew of outer drive housing used on YM330D models.
Reinstall axle as described in para-
graph 5, selecting correct thickness of
thrust washers (56 and 70) which will
limit end play of axle to less than 0.2 mm
(0.0079 in.) without binding.
ENGINE
AND CLUTCH
FRONT SPLIT
All Models
40. It is necessary to separate the
front axle, radiator and front frame
from tractor for some work including
service to the timing gears and cover.
Detach ground cable from battery,
disconnect headlight wire, disconnect
hood holding bracket, then unbolt and
remove hood. Disconnect battery cable
from starter, remove fan belt guard and
drain cooling system. Disconnect air in-
take hose and overflow from expansion
tank if installation interferes with
separation. Disconnect upper and lower
radiator hoses. Detach radiator support
rod and steering drag link. Block rear
wheels and support tractor under clutch
housing. Insert blocks between sides of
front frame to prevent tipping. On
models with front wheel drive, unbolt
drive shaft cover, loosen clamps then
slide front cover toward rear. Discon-
nect spring loaded drive shaft collar, be-
ing careful not to lose balls. Rear of
drive shaft can be similarly detached to
remove drive shaft. On all models, sup-
port front frame and radiator assembly,
unbolt frame side rails from engine, then
roll front end away from tractor.
Reattach front end in reverse of
separation procedure. Tighten screws
which attach frame side rails to engine
to 79-97 N-m (58,27-71.54 ft.-lbs.) tor-
que.
Fig. 33Cross-section showing Instailatlon of
seals (18 and 17). The upper seal (18) is dust seai;
iower seai (17} is oil seal.
14
SHOP MANUAL
CLUTCH SPLIT
All Models
41. To separate tractor between
engine and clutch housing, observe the
following procedure.
Detach ground cable from battery,
shut fuel off and disconnect fuel outlet
line from filter housing. Detach filter
housing from rear of en^ne and move
filter toward rear. On YM135 and
YM135D models, detach the battery
positive cable, then remove the battery.
On all models, detach hydraulic lines
from hydraulic pump and throttle
linkage from injection pump. Disconnect
tachometer cable, then move cable and
housing back out of the way. Disconnect
interfacing wires from st ar t er .
temperature sensor, thermostart, oil
pressure sensor, alternator and head-
lights, then move wires back out of the
way. Detach steering drag link from pit-
man arm. On four wheel drive models,
unbolt drive shaft cover, loosen clamps,
then slide front cover toward rear.
Disconnect spring loaded drive shaft col-
lar, being careful not to lose drive balls.
Rear of drive shaft can be similarly
detached to remove drive shaft. On all
models, block rear wheels, support trac-
tor under clutch housing' and attach
movable overhead hoist to engine.
Remove screws attaching clutch housing
to engine, then carefully roll front of
tractor away from clutch housing.
When assembling, observe the follow-
ing: Be sure that both return springs are
attached to throw out bearing and that
Paragraphs 41-42
front and rear sections of tractor are
aligned before attempting to rejoin.
Engage pto and turn pto output shaft
while pushing tractor together. Tighten
clutch housing to engine fasteners to the
appropriate torque. All 8 mm screws
and nuts should be tightened to 23-30
N-m (17-22 ft.-lbs.) torque; 10 mm
fasteners should be tightened to 45-58
N-m (33-42 ft.-lbs.) torque; 12 mm
fasteners should be tighteneci to 79-97
N-m (58.3-71.5 ft.-lbs.) torque.
R&R ENGINE WITH CLUTCH
All Models
42. To remove the engine and clutch
assembly from tractor, first separate
front axle, frame and radiator as outlin-
89
Fig. 35 - Exploded view of front axle used on yM330D models. Refer to Fig. 32 for legend except the following.
A. Screws 55. Front pivot bracket
D. Dipstick (includes bushing
42. Left axle housing 72)
43. Roll pin 56. Thrust washer
44. Shims (same as (same as 70)
100) 57. Center housing
45. Carrier bearinjj: 58. Shims
(6012) 59. Drive pinion
i 46. Snap ring (same as 60. Taper roller bear-
I 48) ing (32007-same as
' 47. Drive axle 63)
48. Snap ring (same as 61. "0" ring
46) 62. Pinion housing
49. Gasket 63. Taper roller bear-
50. Cover ing (32007-same as
51. Gasket 60)
64. Spacer
65. "0" ring
66. Seal collar
67. Oil seal (TC45629)
68. Shim
69. Nut
70. Thrust washer
(sane as 56)
71. Rear pivot bracket
(same as 55)
72. Bushing (75x80x30
mm)
73. Rubber boot
74. Snap ring
75. Steel ball (11/32-in.)
76. Coupling
77. Spline seal
78. Washer
79. Spring
80. Cotter pin
81. Drive shaft
82. "0" ring
83. Gasket
84. Drive shaft front
cover
85. Clamp
86. Boot
87. Clamp
88. Drive shaft rear
cover
89. Gasket
91. Bushing (40x2x22.5
mm)
92. Ring gear
93. Side gear thrust
washer
94. Side gear
95. Thrust washer
96. Pinions
97. Pinion shaft
98. Differential hous-
ing
99. Right axle housing
100. Shims (same as 44)
101. Roll pins
IS
Paragraphs 45-47
ed in paragraph 40, then proceed as
follows:
Shut fuel off and disconnect fuel outlet
line from filter housing. Detach filter
housing from rear of engine and move
filter toward rear. Detach hydraulic
lines from hydraulic pump and throttle
linkage from injection pump. Disconnect
tachometer cable, then move cable and
housing back out of the way. Disconnect
interfering wires from st ar t er ,
temperature sensor, thermostart, oil
pressure sensor, alternator and head-
lights, then move wires back out of the
way. Attach movable overhead hoist to
engine, remove clutch housing to engine
screws, then carefully move engine
away from clutch housing.
When reassembling, reverse removal
procedure and observe the following: Be
sure that both springs are attached to
throw out bearing. Cap screws and nuts
should be tightened to correct torques.
The 8 mm fasteners should be tightened
to 23-30 N-m (17-22.1 ft.-lbs.) torque; 10
mm fasteners should be tightened to
45-58 N-m (33.2-42.8 ft.-lbs.) torque and
12 mm nuts and screws should be tight-
ened to 79-97 N-m (58.3-71.5 ft.-lbs.)
torque.
CYLINDER HEAD
All Models
45. REMOVE AND REINSTALL.
To remove the cylinder head, refer to
paragraph 47 and remove rocker arm
cover. Disconnect battery, drain
coolant, remove fan belt, upper radiator
hose and air intake pipe. On YM135 and
YM135D models, remove the alternator.
On models so equipped, remove water
pump. On all models, remove fuel leak-
off and injection lines. Remove injection
nozzles and cylinder head lubrication oil
line. Loosen cylinder head retaining
nuts in reverse of order shown in Fig. 40
or Fig. 41, then unbolt and remove
cylinder head. On some two cylinder
models, one of the six retaining nuts is
located in intake passage.
When reinstalling, coat both sides of
head gasket with "Dow Corning/RTV
Silicon Gasket", "Three Bond No. 50" or
equivalent, then position gasket on block
with rolled edge of gasket around
cylinder bores toward top. The larger
cooling passages in gasket will be at rear
(fiywheel) end of engine. Coat threads
with engine oil and install retaining
nuts. Tighten nuts in sequence shown in
Fig. 40 or Fig. 41. Tighten cylinder head
retaining nut to 152.0-156.9 N-m
(112-116 ft.-lbs.) torque for YM135,
YM135D, YM155 and YM155D models;
171.6-181.4 N-m (127-134 ft.-lbs.) tor-
que for all other models. Rocker arm
support nuts should be tightened to
Fig. 40-Cylinder head shoutd be tightened in
sequence shown for all two cyiinder models.
78.5-98.1 N-m (58-72 ft.-lbs.) torque for
YM135, YM135D, YM155, YM155D
YM240 and YM240D models; 64.7 N-m
(48 ft.-lbs.) torque for all other models.
Refer to paragraph 47 for adjusting
valve clearance. Install rocker arm
cover, then adjust decompression con-
trols as outlined for models with adjust-
ment screws.
46. OVERHAUL. Refer to appropri-
ate paragraphs 51, 48, 49 and 50 for ser-
vicing rocker arms, valves, seats, guides
and springs. Check cylinder head for
fiatness using a straightedge and feeler
gage. On three cylinder models, head
should be fiat within 0.03 mm when
checked across retaining stud holes
longitudinally, laterally and diagonally.
Maximum warpage limit is 0.1 mm
(0.0039 in.). Refer to paragraph 51 for
assembly of rocker arms.
VALVE CLEARANCE
ADJUSTMENT
All Models
47. Recommended valve clearance
(tappet gap) is 0.2 mm (0.008 in.) cold for
inlet and exhaust valves of YM135,
YM135D, YM155 and YM155D; 0.15
mm (0.006 in.) for both inlet and exhaust
valves of all other models. Valve
clearance should be checked after
assembling cylinder head and approx-
imately every 300 hours of operation.
YANMAR
The rocker arm cover for YM195,
YM195D, YM240 and YM240D models
incorporates the inlet air passag:e. On all
models, disconnect decompression link-
age and disconnect or remove interfer-
ing hardware, then unbolt and remove
the rocker arm cover. Check and adjust
valve clearance when piston is at TDC
on compression stroke. TDC mark for
number 1 (rear) cylinder is marked on
crankshaft pulley as shown in Fig. 47.
On two cylinder models the number 2
(front) cylinder is 180 degrees (exactly
V2-turn) from the number 1 cylinder
position. On three cylinder models, the
front (number 3) cylinder top dead
center occurs 240 degrees (exactly
2/3-revolution) after the rear (number 1)
TDC and the center (number 2) piston
reaches TDC exactly 240 degrees after
the front. Usually top dead center is
marked for all cylinders and is identified
by "2T" or "3T"; however, the crankshaft
pulley of some models may have only
one TDC mark which is for rear (number
1) cylinder.
Reinstall rocker arm cover by revers-
ing removal procedure. Adjust decom-
pression lever clearance on YM195,
YM195D, YM240, YM240D, YM330 and
YM330D models as follows. Remove the
small covers from rocker arm cover
above each exhaust valve, then turn
crankshaft until number 1 (rear)
cylinder is at TDC on compression
stroke. Move decompression control to
decompression position. Loosen locknut
(A-Fig. 48), then turn screw (B) until
clearance is 0 without moving valve.
Turn screw (B) in one full turn, then
tighten locknut (A). This adjustment will
hold valve open approximately 0.8 mm
(0.031 in.) when decompression device is
engaged. Turn crankshaft to next
cylinder TDC (180 degrees for 2 cylinder
models, 240 degrees fot* front cylinder of
3 cylinder models) and adjust decom-
pression for next cylinder. On three
cylinder models, rotate crankshaft 240
degrees and adjust decompression for
the center (number 2) cylinder.
Fig. 4i Tighten cyiinder head retaining nuts in
sequence shown for three cyiinder modeis.
Fig. 47-Beginning of infection should occur
when leading mark (i) is ailgned with notch as
shown. When the foHowing mark (T) is aiigned
with notch, piston is at top dead center.
16
SHOP MANUAL Paragraphs 48-51
Fig. 48-View of decompressor lockr)ut (A) and adfusting screw (B). Crosssection drawing shows
method of operation.
New 41.0 mm
(1.6142 in.)
Minimum Limit 36.5 mm
(1.4370 in.)
YM195, YM195D, YM330, YM330D
Free Length-
New 40.0 mm
(1.5748 in.)
Minimum Limit 39.7 mm
(1.5630 in.)
YM240, YM240D
Free Length-
New 42.5 mm
(1.6732 in.)
Minimum Limit 41.0 mm
(1.6142 in.)
Maximum deflection limit is 2 degrees
or approximately 1.43 mm (0.0563 in.).
Be sure to install new guide stem seals
when reassembling using seal protector
and lubricant to prevent damage during
installation.
VALVES AND SEATS
All Models
48. Intake and exhaust valves are not
^interchangeable. Valve seats can be re-
onditioned using 15, 45 and 70 degree
Fstones. Valve face and seat angle for
both inlet and exhaust is 45 degrees.
Recommended seat width is 1.77 mm
(0.0697 in.) for YM135, YM135D,
YM155 and YM155D models; 2.12 mm
(0.0835 in.) for other models. Seats can
be narrowed using 15 and 70 degree
stones. Valve is recessed 1.25 mm
(0.0492 in.) below surface of head on
YM330 and YM330D models and should
not be recessed more than 1.85 mm
(0.0728 in.). On two cylinder models,
valve should not be recessed more than
0.5 mm (0.0197 in.). Renew valve if
margin is not even or is less than
V2 thickness of new valve. Valve stems
and guides should be within limits which
follow.
YM135, YM135D, YM155, YM155D
Valve Stem Diameter-
Desired 6.95-7.04 mm
(0.2736-0.2772 in.)
Wear Limit 6.9 mm
(0.2717 in.)
Valve Guide Diameter-
Inlet, Desired 7.0-7.015 mm
(0.2756-0.2762 in.)
Wear Limit 7.08 mm
(0.2787 in.)
Exhaust, Desired 7.02-7.05 mm
(0.2764-0.2776 in.)
Wear Limit 7.08 mm
(0.2787 in.)
Valve Stem to Guide Clearance-
Inlet, Desired 0.040-0.065 mm
(0.0016-0.0026 in.)
Wear Limit .0.15 mm
(0.0059 in.)
Exhaust, Desired 0.045-0.070 mm
(0.0018-0.0028 in.)
Wear Limit 0.15 mm
(0.0059 in.)
YM195, YM195D, YM240, YM240D,
YM330, YM330D
Valve Stem Diameter-
Desired 7.96-7.97 mm
(0.3134-0.3138 in.)
Wear Limit 7.9 mm
(0.3110 in.)
Valve Guide Diameter, Inlet & Exhaust-
Desired 8.010-8.025 mm
(0.3154-0.3159 in.)
Wear Limit 8.08 mm
(0.3181 in.)
Valve Stem to Guide Clearance-
Desired 0.045-0.070 mm
(0.0018-0.0028 in.)
Wear Limit 0.15 mm
(0.0059 in.)
Install new valve stem seals whenever
valves are serviced.
VALVE SPRINGS
All Models
49. Valve springs are interchangeable
for inlet and exhaust valves. Renew spr-
ings which are distorted, heat discolored
or fail to meet test specifications which
follow:
YM135, YM135D, YM155, YM155D
Free Length-
VALVE GUIDES
All Models
50. Inlet and exhaust valve guides are
not interchangeable. Inlet valve guide is
usually marked by a second (identifying)
groove and passage end of exhaust
guide is counterbored. Stem to guide
clearance should be 0.040-0.065 mm
(0.0016-0.0026 in.) for inlet valves of
YM135, YM135D, YM155 and YM155D
models. Exhaust guides for YM135,
YM135D, YM155, YM155D and for both
inlet and exhaust valves of all other
models should have 0.045-0.070 mm
(0.0018-0.0028 in.) stem to valve guide
clearance. Valve and/or guide should be
renewed if clearance exceeds 0.15 mm
(0.0059 in.). New guides should be press-
ed into cylinder head until the groove in
guide is just above upper surface of
cylinder head.
ROCKER ARMS
AND PUSH RODS
All Models
51. Rocker arms can be removed
after removing rocker arm cover.
Rocker arms for one cylinder are located
on the shafts of a support stand which is
retained to cylinder head by one stud
nut. The diameter of the rocker arm
shaft should be 13.98-14.00 mm
(0.5504-0.5512 in.) with wear limit of
13.90 mm (0.5472 in.) for YM135,
YM135D, YM155 and YM155D models,
16.98-17.00 mm (0.6685-0.6693 in.) with
wear limit of 16.90 mm (0.6654 in.) for
17
Paragraphs 52-54 YANMAR
F RO NT
other models. Bushing pressed into
rocker arm should have inside diameter
of 14.024-14.034 mm (0.5521-0.5525 in.)
with wear limit of 14.10 mm (0.5551 in.)
for YM135, YM135D, YM155 and
YM155D models, 17.016-17.034 mm
(0.6699-0.6706 in.) with wear limit of
17.15 mm (0.6752 in.) for other models.
Clearance between bushing and shaft
should not exceed 0.15 mm (0.0059 in.)
for any model.
On two cylinder models, two different
rocker arms are used; however, once
wear pattern is established, rocker arms
should not be relocated to another shaft.
On three cylinder models, rocker arms
with different offsets are used as shown
in Fig. 51.
Push rods should be straight and can
be checked by rolling on a fiat plate.
Length of new push rod is 165.2 mm (6.5
in.) for YM135, YM135D, YM155 and
YM155D models; 197 mm (7.75 in.) for
other models.
On all models, loosen locknuts and
turn adjustment screws out toward top
before installing rocker arms and sup-
port. Be sure that dowel pin correctly
engages hole in support. Tighten rocker
arm support retaining nuts to 78.45-
98.07 N-m (58-72 ft.-lbs.) torque for
YM135, YM135D, YM155 and YM155D
models; 64.72 N-m (48 ft.-lbs.) torque
for other models.
CAM F O LLO WERS
All Models
52. All models are equipped with
mushroom type cam followers which can
TIMING MARKS
Fig. 51 View of rocker arms
used on three cyiinder
models. Notice that both
rocker arms for front (No. 3)
cyiinder are different than
arms used for other
cylinders.
only be removed from below after
removing camshaft as outlined in para-
graph 60 or 61 and oil pan. Check sur-
face of cam follower which contacts
camshaft and renew followers if worn.
Also check camshaft carefully if follower
shows wear and renew camshaft if chip-
ped, broken, scored or otherwise worn.
Cam follower OD is 10.976-10.994 mm
(0.4321-0.4328 in.). Clearance between
cam follower and block bore should be
0.006-0.035 mm (0.0002-0.0014 in.) with
maximum limit of 0.10 mm (0.0039 in.).
VALVE T IMING
All Models
53. Refer to paragraph 54 or 55 for
removal of timing gear cover. Valves are
properly timed when timing marks are
aligned as shown in Fig. 52. Marks align
every second revolution of crankshaft.
T IMING GEAR CO VER
YM135, YM135D, YM155, YM155D
Models
54. To remove the timing gear cover,
first split front of tractor as described in
7
Fig. 54 Cross-section of timing gear cover
showing governor of yM135, rMtd5D, YM155
and YM155D models. Refer to Fig. 54A for
iegend.
paragraph 40. Remove fan belt, fan,
crankshaft pulley and breather/gover-
nor control cover. Disconnect
tachometer cable from housing and
linkage from governor control. Refer to
paragraph 87 and remove injection
pump. Unbolt and remove the timing
gear cover.
Be sure that all of old gasket is remov-
ed, then coat new gasket with sealer
before installation. Be sure that sleeve
(17-Fi g. 54A) correctly engages
weights (20) and be careful not to bend
or otherwise damage governor control
linkage when installing cover. Refer to
paragraph 101 for governor ad-
justments if correct adjustment is ques
tioned or if any adjustment point has
been disturbed. Tighten retainingi
screws to 22.56-29.42 N-m (16.6-21.7
ft.-lbs.) torque. Install crankshaft pulley
after lubricating seal surface and
tighten retaining screw to 117.7-147.1
N-m (87-108 ft.-lbs.) torque. Refer to
paragraph 87 for installation of fuel
4
Fig. 52 View of timing marks on camshaft and
crankshaft gears.
Fig. 54AExpioded view of
timing gear cover, governor
and related parts used on
YM135, YM135D, YM155 and
YM155D modeis.
1. Governor spring
2. Washer
3. Spring body
4. Washer
5. Locknut
6. High speed stop screw
7. Damper spring
8. Locknut
9. Lock cap nut
10. Pivot shaft
11. Steel ball (9/32-inch)
12. External speed control
lever
13. "O"ring
14. Shaft
15. Internal speed control lever
16. Follower lever
17. Governor sleeve
18. Governor lever
19. Pins
20. Weights
21. Bracket
22. Guide sleeve
23. Injection pump
24. Hydraulic pump and drive
gear
18
SHOP MANUAL
16 3 18
Fig. SS-Cross-section of governor assembly for YM330 and YM330D models. Refer to Fig. SSA for
legend. Models YMISS, YM19SD, YM240 and YM240D are similar.
pump and paragraph 40 for installing
front axle and frame.
YM1 95, YM1 95D, YM240,
YM240D, YM330 and YM330D
Models
55. To remove the timing gear cover,
first split front of tractor as described in
paragraph 40. Remove fan belt, fan,
hydraulic pump and crankshaft pulley.
Disconnect tachometer drive cable from
housing. Remove injection pump
chamber cover plate, then disconnect
governor spring (1 - Fig. 55), remove pin
(2) and detach governor link from rack.
Be careful not to deform spring when
detaching spring from speed control
lever. Unbolt and remove timing gear
cover.
Be sure that all of old gasket is remov-
ed, then coat new gasket with sealer
before installation. Be sure that sleeve
1. Governor spring
2. Clip
3. Adjusting nut
4. Adjusting nuts
5. Locknut
6. High speed stop screw
7. Torque spring and shaft
assy.
8. Locknut
9. Lock cap nut
(17-Fi g. 55A) correctly engages
weights (20) and be careful not to bend
or otherwise damage governor link (16)
when installing cover. Refer to para-
graph 103 for governor adjustments if
correct adjustment is questioned or if
any adjustment point (3,4,5,6 or 7) has
been disturbed. Stud nuts attaching tim-
ing gear cover should be tightened to
24.52-26.58 N-m (16.6-19.5 ft.-lbs.) tor-
que. Install crankshaft pulley after
lubricating seal surface and tighten re-
taining screw to 63.74 N*m (47 ft.-lbs.)
torque. Tighten stud nuts retaining
hydraulic pump to 68.65 N m (50
ft.-lbs.) torque.
TIMING GEARS
YM1 35, YM1 35D, YM1 55 and
YM1 55D Models
56. Refer to paragraph 54 for
removal of timing gear cover. Backlash
Fig. 554 - Exploded view of
timing gear cover and gover-
nor assembly for yM330 and
YM330D models. Two
cyiinder yMT95, YM195D,
YM240 and YM240D models
are similar.
10. Attaching screw
11. Spring tab
12. External speed control
lever
13. "0" ring
14. Shaft
15. Internal speed control lever
16. Governor link
17. Governor sleeve
18. Governor lever
19. Pins
20. Weights
21. Bracket
22. Pivot support
23. Injection pump
24. Spacer
Paragraphs 55-60
between camshaft and crankshaft gears
should be 0.08-0.16 mm (0.0031-0.0063
in.) with wear limit of 0.3 mm (0.0118
in.). Crankshaft gear can be pulled from
crankshaft using threaded holes in gear
and a suitable puller. Align keyway with
key and timing marks (Fig. 52), then use
threaded hole in crankshaft to push gear
onto crankshaft.
Refer to paragraph 60 to remove cam-
shaft if camshaft gear is to be removed.
YM1 95, YM1 95D, YM240,
YM240D, YM330 and YM330D
Models
57. Refer to paragraph 55 for
removal of timing gear cover. Backlash
between camshaft and crankshaft gears
should be 0.08-0.16 mm (0.0031-0.0063
in.) with wear limit of 0.3 mm (0.0118
in.). Backlash between camshaft gear
and hydraulic pump drive gear and bet-
ween crankshaft gear and engine oil
pump drive gear should also be less than
0.3 mm (0.0118 in.).
The crankshaft gear can be pulled
from crankshaft using threaded holes in
gear and a suitable puller. Align keyway
with key and timing marks (Fig. 52),
then use threaded end of crankshaft and
nut to push gear onto crankshaft.
Refer to paragraph 61 to remove cam-
shaft if camshaft gear is to be removed.
CAMSHAFT
YM1 35, YM1 35D, YM1 55 and
YM1 55D Models
60. To remove the camshaft, first
remove the cylinder head as outlined in
paragraph 45, then refer to paragraph
54 and remove the timing gear cover.
Use magnetic holding tools to raise cam
followers away from camshaft. Remove
camshaft bearing retaining screw (Fig.
59), then pull camshaft and gear for-
ward out of cylinder block. Camshaft
gear and front bearing can be pressed
from camshaft after removing nut and
governor weight assembly. Measure
camshaft lobes and journals against the
values which follow.
Rear (Flywheel) Journal -
Diameter, New 29.939-29.960 mm
(1.1787-1.1795 in.)
Wear Limit 29.90 mm
(1.1772 in.)
Clearance in Bushing,
Desired 0.04-0.081 mm
(0.0016-0,0032 in.)
Wear Limit 0.15 mm
(0.0059 in.)
Center Journal -
Diameter, New 41.925-41.950 mm
(1.6506-1.6516 in.)
Clearance in Bushing,
Desired 0.05-0.10 mm
(0.0020-0.0039 in.)
19
Paragraphs 61-66
YANMAR
Wear Limit 0.15 mm
(0.0059 in.)
Inlet and Exhaust Lobe-
Height New 35.0 mm
(1.3780 in,)
Fuel Pump Lobe-
Height New 45.0 mm
(1.7717 in.)
When supported at ends in lathe
centers, runout measured at center
bearing should be less than 0.05 mm
(0.0020 in.). Press front bearing on cam-
shaft, position key in slot, then press
camshaft gear onto camshaft. Install
fuel pump cam lobes with marks toward
front. Both fuel pump cam lobes are
identical, but must engage key in cam-
shaft. Tighten retaining nut securely.
The cam followers can be withdrawn
from bores after removing camshaft and
oil pan. Sepcifications for cam followers
are listed in paragraph 52.
Locate camshaft in cylinder block
after cam followers are positioned at top
of travel in block bores. Install bearing
retainer screw through hole in web of
camshaft gear. Refer to paragraph 87
for installing fuel injection pump,
paragraph 54 for installing timing gear
cover and paragraph 45 for installing
cylinder head.
YM195, YM195D, YM240,
YM240D, YM330 and YM330D
Models
61. To remove camshaft, first remove
the cylinder head as outlined in para-
graph 45, then refer to paragraph 55 to
remove the timing gear cover and para-
graph 89 to remove the fuel injection
pump. Use magnetic holding tools to
raise cam followers away from cam-
shaft. Remove bearing retaining screw
(Fig. 59), then pull camshaft and gear
forward out of cylinder block. Camshaft
gear and front bearing can be pressed
from camshaft after removing nut (left
hand thread) and governor weight.
Measure camshaft lobes and journals
against the values which follow.
Rear (Flywheel) Journal -
Diameter, New 33.925-33.950 mm
(1.3356-1.3366 in.)
Wear Limit 33.90 mm
(1.3346 in.)
Clearance in Bushing,
Desired 0.05-0.10 mm
(0.0020-0.0039 in.)
Wear Limit 0.15 mm
(0.0059 in.)
Center Journal -
Diameter, New 45.925-45.950 mm
(1.8081-1.8091 in.)
Wear Limit 45.88 mm
(1.8063 in.)
Clearance in Bushing,
Desired 0.05-0.10 mm
(0.0020-0.0039 in.)
Wear Limit 0.15 mm
(0.0059 in.)
Inlet and Exhaust Lobe,
Desired 38.63 mm
(1.5209 in.)
Wear Limit 38.13 mm
(1.5012 in.)
Fuel Pump Lobe,
Desired 34.9 mm
(1.3740 in.)
Wear Limit 34.8 mm
(1.3701 in.)
When supported at ends in lathe
centers, runout measured at center
bearing should be less than 0.05 mm
(0.0020 in.). Press front bearing on cam-
shaft, position key in slot, then press
camshaft gear on camshaft.
The cam followers can be withdrawn
from bores after removing camshaft and
oil pan. Specifications for cam followers
are listed in paragraph 52.
Locate camshaft in cylinder block
after cam followers are positioned at top
of travel in block bores. Install bearing
retainer screw through hole in web of
camshaft gear. Refer to paragraph 89
for installing fuel injection pump,
paragraph 55 for installing timing gear
cover and paragraph 45 for installing
cylinder head.
ROD AND PISTON UNITS
All Models
65. Connecting rod and piston units
are removed from above after removing
cylinder head as outlined in paragraph
45 and removing oil pan. Remove con-
necting rod cap and push piston and rod
assembly up out of cylinder block.
When assembling, space ring end gaps
at 90 degree intervals from each other
and 45 degrees from piston pin center-
line. Coat pistons, liners and ring com-
pressor with clean engine oil. Identi-
fication marks on connecting rods
should be toward rear (flywheel) end of
engine. Tighten connecting rod cap re-
taining screws to 44.13-49.03 N-m
(33-36 ft.-lbs.) for YM135, YM135D,
YM155, YM155D, YM240 and YM240D
Fig. 59 View of governor weights and brackets
assembled on cam gear typical of many modeis.
The camshaft of ail models is retained by screw
identified by arrow.
models, 63.74 N-m (47 ft.-lbs.) torque
for YM195, YM195D, YM330 and
YM330D models.
PISTONS, SLEEVES AND RINGS
All Models
66. Measure stand out of cylinder
liners (sleeves) above the cylinder block.
A puller should be used to pull wet type
cylinder liners from block bores. Be sure
that manufacturers marks on all rings
are toward top when assembling rings to
pistons. Check clearances against the
values which follow:
YM135, YM135D
Liner Stand Out 0.05-0.13 mm
(0.0020-0.0051 in.)
Cylinder Liner I D-
New 73.000-73.030 mm
(2.8740-2.8752 in.)
Wear Limit 73.17 mm
(2.8807 in.)
Piston Skirt to Cylinder Liner-
Clearance, New 0.108-0.173 mm
(0.0043-0.0068 in.)
Wear Limit 0.3 mm
(0.0113 in.)
Piston Skirt Diameter at Bottom of
Skirt/Right Angles to Piston Pi n-
New 72.891-72.922 mm
(2.8697-2.8709 in.)
Wear Limit 72.80 mm
(2.8661 in.)
Ring End Gap-
All Rings, Desired 0.2-0.4 mm
(0.0079-0.0157 in.)
Wear Limit 1.5 mm
(0.0591 in.)
Ring to Groove Side Clearance -
Desired-Top 0.050-0.085 mm
(0.0020-0.0033 in.)
2nd,3rd & Bottom.. 0.020-0.055 mm
(0.0008-0.0022 in.)
Wear Limit-Top,2nd & 3rd . . . 0.2 mm
(0.0079 in.)
Bottom 0.15 mm
(0.0059 in.)
YM155, YM155D
Liner Stand Out 0.05-0.13 mm
(0.0020-0.0051 in.)
Cylinder Liner I D-
New 75.000-75.030 mm
(2.9528-2.9539 in.)
Wear Limit 75.17 mm
(2.9594 in.)
Piston Skirt to Cylinder Liner-
Clearance, New 0.108-0.173 mm
(0.0043-0.0068 in.)
Wear Limit 0.3 mm
(0.0118 in.)
Piston Skirt Diameter at Bottom of
Skirt/Right Angles to Piston Pi n-
New 74.891-74.922 mm
(2.9485-2.9497 in.)
Wear Limit 74.80 mm
(2.9449 in.)
20
SHOP MANUAL
Paragraph 70
Ring End Gap-
All Rings, Desired 0.2-0.4 mm
(0.0079-0.0157 in.)
Wear Limit 1.5 mm
(0.0591 in.)
Ring to Groove Side Clearance-
Desired-Top 0.050-0.085 mm
(0.0020-0.0033 in.)
2nd,3rd & Bottom.. 0.020-0.055 mm
(0.0008-0.0022 in.)
Wear Limit-Top,2nd & 3rd 0.2mm
(0.0079 in.)
Bottom 0.15 mm
(0.0059 in.)
YM195, YM195D
Liner Stand Out 0.07-0.15 mm
(0.0028-0.0059 in.)
Cylinder Liner I D-
New 84.000-84.035 mm
(3.3071-3.3085 in.)
Wear Limit 84.2 mm
(3.3150 in.)
Piston Skirt to Cylinder Liner-
Clearance, New 0.077-0.142 mm
(0.0030-0.0056 in.)
Wear Limit 0.3 mm
(0.0118 in.)
Piston Skirt Diameter at Bottom of
Skirt/Right Angles to Piston Pi n-
New 83.893-83.923 mm
(3.3029-3.3041 in.)
Wear Limit 83.80 mm
(3.2992 in.)
Ring End Gap-
All Rings, Desired 0.3-0.5 mm
(0.0118-0.0197 in.)
Wear Limit 1.5 mm
(0.0591 in.)
Ring to Groove Side Clearance -
Desired-Top 0.055-0.095 mm
(0.0022-0.0037 in.)
2nd,3rd & Bottom.. 0.020-0.055 mm
(0.0008-0.0022 in.)
Wear Limit-Top .0.3 mm
(0.0118 in.)
2nd & 3rd. 0.2 mm
(0.0078 in.)
Bottom 0.15 mm
(0.0059 in.)
YM240, YM240D
Liner Stand Out 0.07-0.10 mh.
(0.0028-0.0039 in.)
Cylinder Liner I D-
New 90.000-90.035 mm
(3.5433-3.5447 in.)
Wear Limit 90.20 mm
(3.5512 in.)
Piston Skirt to Cylinder Liner-
Clearance, New 0.108-0.173 mm
(0.0043-0.0068 in.)
Wear Limit 0.3 mm
(0.0118 in.)
'Piston Skirt Diameter at Bottom of
Skirt/Right Angles to Piston Pi n-
New 89.862-89.892 mm
(3.5379-3.5391 in.)
Wear Limit 89.8 mm
(3.5354 in.)
Ring End Gap-
All Rings, Desired .. .0.3-0.5 mm
(0.0118-0.0197 in,)
Wear Limit 1.5 mm
(0.0591 in.)
Ring to Groove Side Clearance -
Desired-Top 0.080-0.115 mm
(0.0031-0.0045 in.)
2nd,3rd & Bottom. . 0.020-0.055 mm
(0.0008-0.0022 in.)
Wear Limit-Top 0.3 mm
(0.0118 in.)
2nd&3rd 0.2 mm
(0.0079 in.)
Bottom 0.15 mm
(0.0059 in.)
YM330, YM330D
Liner Stand Out 0.07-0.15 mm
(0.0028-0.0059 in.)
Cylinder Liner I D-
New 84.000-84.035 mm
(3.3071-3,3085 in,)
Wear Limit 84,2 mm
(3.3150 in.)
Piston Skirt to Cylinder Liner-
Clearance, New 0.077-0,142 mm
(0.0030-0,0056 in.)
Wear Limit 0.3 mm
(0.0118 in.)
Piston Skirt Diameter at Bottom of
Skirt/Right Angles to Piston Pi n-
New 83.893-83.923 mm
(3.3029-3.3041 in.)
Wear Limit 83.80 mm
(3.2992 in.)
Ring End Gap-
All Rings, Desired 0.3-0.5 mm
(0,0118-0.0197 in.)
Wear Limit 1.5 mm
(0.0591 in.)
Ring to Groove Side Clearance -
Desired-Top 0,055-0.095 mm
(0,0022-0.0037 in.)
2nd,3rd & Bottom.. 0.020-0.055 mm
(0.0008-0.0022 in.)
Wear Limit-Top 0.3 mm
(0.0118 in.)
2nd,3rd & Bottom 0.25 mm
(0.0098 in.)
The top ring is chromium plated, the
second and third rings have a tapered
face and the bottom (oil control) ring has
beveled edges for better scraping action.
It is important to install all piston rings
with marked side of ring toward top
(closed end) of piston.
If cylinder sleeves are removed, be
sure to clean grooves thoroughly and in-
stall new "0" rings in grooves. Coat liner
with waterproof paint and insert sleeve
into block before paint dries. If liner
stand out is too high, check to be sure
block and sleeve are clean and free of
rust, scale or burrs.
PISTON PIN
All Models
70. Piston pin is a transition fit in
piston bores with slight interference fit
or small amount of clearance. Piston pin
should have recommended clearance in
connecting rod small end bushing. To
remove piston pin, remove retaining
rings from piston, heat piston to 80-100
degrees C, then press piston pins from
piston bores. Refer to the following
specification data:
YM135, YM135D, YM155, YM155D
Piston Pin
Diameter 29.989-30.000 mm
(0.9053-0.9058 in.)
Clearance In Rod Small End Bushing-
Desired 0.025-0,049 mm
(0.0010-0.0019 in.)
Wear Limit 0.11 mm
(0.0043 in.)
Diameter of Pin Bushing In Connecting
Rod-
Desired 23.025-23,038 mm
(0.9065-0.9070 in.)
Pin Fit In Piston Bores -
Desired, Interference to
Clearance -0,004 to +0.008 mm
(-0.0002 to +0.0003 in.)
YM195, YM195D, YM240, YM240D
Piston Pin
Diameter 29.989-30,000 mm
(1,1807-1,1811 in,)
Clearance In Rod Small End Bushing-
Desired 0.025-0.049 mm
(0.0010-0.0019 in.)
Wear Limit 0.15 mm
(0.0059 in,)
Diameter of Pin Bushing In Connecting
Rod-
Desired 30.025-30.038 mm
(1.1821-1.1826 in.)
Pin Fit In Piston Bores-
Desired, Interference to
Clearance -0,005 to +0.019 mm
(-0,0002 to +0.0007 in.)
YM330, YM330D
Piston Pin Diameter . . . 29.95-30.00 mm
(1.1791-1.1811 in.)
Clearance In Rod Small End Bushing-
Desired 0,025-0.049 mm
(0.0010-0,0019 in.)
Wear Limit 0.15 mm
(0,0059 in.)
Diameter of Pin Bushing In Connecting
Rod-
Desired 30,025-30.038 mm
(1,1821-1.1826 in.)
Wear Limit 30.1 mm
(1.1850 in.)
Pin Fit In Piston Bores-
Desired, Interference to
Clearance -0.005 to +0.019 mm
(-0.0002 to +0.0007 in.)
21
Paragraph 71
Side Clearance of Rod Between Piston
Bosses -
Desired 0.2-0.5 mm
(0.0079-0.0197 in.)
Wear Limit 0.55 mm
(0.0217 in.)
Align both holes in bushing with holes
in connecting rod. When assembling
pistons, pins and connecting rods,
observe the following:
Install one piston pin retaining snap
ring in one groove of each piston, then
heat pistons to 80-100 degrees C
(176-212 degrees F). Coat piston pins
and rod bushings with clean engine oil
and install cool pin through rod bushing
and heated piston. Be sure to install se-
cond retaining ring in piston groove.
After cooling, connecting rod should
move smoothly on piston pin.
CONNECTING RODS
AND BEARINGS
All Models
71. Connecting rod crankpin bearing
inserts are available in standard size and
0.25 mm undersize; however, be sure
that undersize inserts are obtained
before machining crankshaft crankpins.
Rod bearing inserts can be installed
from below after removing oil pan.
Refer to the following specification data:
YM135, YM135D, YM155, YM155D
Piston Pin Bushing I D-
Desired 23.025-23.038 mm
(0.9065-0.9070 in.)
Wear Limit 23.1 mm
(0.9094 in.)
Crankpin Journal Diameter-
Desired 46.950-46.964 mm
(1.8484-1.8490 in.)
Wear Limit 46.920 mm
(1.8472 in.)
Connecting Rod Bearing to Crankpin
Clearance -
Desired 0.036-0.095 mm
(0.0014-0.0037 in.)
Wear Limit 0.20 mm
(0.0079 in.)
Rod Side Play on Crankpin -
Desired 0.15-0.35 mm
(0.0059-0.0138 in.)
YANMAR
Rod Bolt Torque 44.13-49.03 N-m
(33-36 ft.-lbs.)
YM195, YM195D, YM240, YM240D,
YM330, YM330D
Piston Pin Bushing I D-
Desired 30.025-30.038 mm
(1.1821-1.1826 in.)
Wear Limit 30.1 mm
(1.1850 in.)
Crankpin Journal Diameter-
Desired 53.950-53.964 mm
(2.1240-2.1246 in,)
Wear Limit 53.91 mm
(2.1224 in.)
Connecting Rod Bearing to Crankpin
Clearance -
Desired 0.036-0,095 mm
(0.0014-0.0037 in.)
Wear Limit 0.15 mm
(0.0059 in.)
Rod Side Play on Crankpin -
Desired 0.15-0.35 mm
(0.0059-0.0138)
Wear Limit 0.50 mm
(0.0197 in.)
Rod Bolt Torque 63.74 N-m
(47 ft.-lbs.)
13
19
41
40
Fig. 60 - Exploded view of cylinder block and related parts used on YM135, YM135D, YM155 and YM155D models. Refer to Fig. 54A for governor assembly. ^
16. Oil filter
1. Screw 10. Crankshaft 19. Bearings and spacer 26. Camshaft 40. Governor and hydraulic ^
2! Crankshaft pulley 11. Rear main bearing 21. Nut 27. Cam follower pump drive gear
3. Front oil seal 12. Rear bearing and seal 22. Governor weights 29. Oil pressure sender 41. Drive shaft
5 Crankshaft gear housing 23. Camshaft gear 37. Tachometer drive 42. Adapter
6 Front main bearing 13. Rear oil seal 24. Retaining screw 38. Injection pump cam lobes
9' Thrust bearings 15. Oil pump 25. Camshaft front bearing 39. Spacer
43. Hydraulic pump
44. Shim
22
SHOP MANUAL
Paragraph 72
CRANKSHAFT AND
MAIN BEARINGS
Two Cylinder Models
72. The crankshaft of two cylinder
nnodels is supported in two main bear-
ings and crankshaft end thrust is taken
by a thrust washer (9-Fig. 60 or Fig.
61) located at each end of the crank-
shaft. To remove the crankshaft and/or
main bearings from all models, proceed
as follows:
Separate the front axle, frame and
radiator as outlined in paragraph 40,
then refer to paragraph 42 to complete
removal of engine. Refer to paragraph
45 to remove the cylinder head and to
paragraph 54 to remove the timing gear
cover. Refer to paragraph 65 to remove
the rod and piston units and to
paragraph 131 for removing the clutch
and flywheel. Pull crankshaft gear from
crankshaft and remove the oil pick-up
tube. Turn the engine so that weight
rests on front face of cylinder block and
rear end is up. Weight of crankshaft
should be vertical against front of
engine.
Unbolt and remove rear main bearing
and seal housing, being careful not to
damage the rear thrust bearing. With-
draw crankshaft from cylinder block.
Use care to prevent damage to all parts
^including the front thrust bearing which
will be free to fall as the crankshaft is
lifted out of front main bearing. Inspect
main bearings and crankshaft using the
following specification data.
YM135, YM135D, YM155, YM155D
Crankshaft Main Journal (Both)
Diameter -
New 64.950-64.964 mm
(2.5571-2.5576 in.)
Wear Limit 64.91 mm
(2.5555 in.)
Main Bearing (Both) Diameter-
New 65.00-65.049 mm
(2.5591-2.5610 in.)
Wear Limit 65.10 mm
(2.5630 in.)
Main Journal to Bearing Clearance -
New 0.036-0.099 mm
(0.0014-0.0039 in.)
Wear Limit 0.2 mm
(0.0079 in.)
YM195, YM195D, YM240, YM240D
Crankshaft Main Journal (Both)
Diameter-
New 69.950-69.964 mm
(2.7539-2.7545 in.)
Wear Limit 69.90 mm
(2.7520 in.)
Main Bearing (Both) Diameter-
New 70.00-70.06 mm
(2.7559-2.7583 in.)
Wear Limit 70.10 mm
(2.7598 in.)
Main Journal to Bearing Clearance-
New 0.036-0.099 mm
(0.0014-0.0039 in.)
Wear Limit 0.2 mm
(0.0079 in.)
The front main bearing (6-Fig. 60 or
Fig. 61) is pressed into cylinder block
and the rear main bearing (11) is pressed
into rear housing on all models. Be sure
to align oil holes in bearings with
passages in block and housing when
pressing new bearings into position.
Rear seal (13) should be pressed into
rear bore of housing with lip toward
front (inside).
The thrust washers which limit crank-
shaft end play should be 2.9-3.0 mm
(0.1142-0.1181 in.) thick with wear limit
of 2.75 mm (0.1083 in.). Crankshaft end
play should be 0.1-0.2 mm
(0.0039-0.0079 in.) with maximum limit
of 0.4 mm (0.0157 in.). Be sure that all
bearings and seals are lubricated with
engine oil and stand cylinder block on
front face so that crankshaft can be in-
serted from above. Position the front
thrust washer in block recess with oil
channels toward crankshaft and lug
engaging notch in block. Lower the
crankshaft into block. Use grease to
stick thrust washer into rear bearing
and seal housing. Be sure that lubrica-
tion grooves are toward crankshaft and
lug on thrust washer engages notch in
housing. Install rear bearing and seal
44
14
1. Nut
9. Thrust beariniars
44. Shim
Fig. 61 - Partially exploded view of timing gears, camshaft and crankshaft for YM195, YM195D, YM240 and YM240D models. Refer to Fig, $2 for legend ex-
cept the following.
23
Paragraph 73
housing with thrust washer carefully us-
ing proper thickness of gasket (44). The
thickness of gasket (44) should be
selected to adjust crankshaft end play
within limits of 0.1-0.2 mm
(0,0039-0.0079 in.). Screws attaching
rear bearing housing should be tighten-
ed to 37.27 N-m (27.5 ft.-lbs.) torque.
Make sure that crankshaft rotates freely
after assembly. Complete assembly by
reversing disassembly procedure. Fly-
wheel retaining screws should be
tightened to 63.74-68.65 N-m (47-50
ft.-lbs.) torque for YM135, YM135D,
YM155 and YM155D models. Flywheel
retaining nut used on YM195, YM195D,
YM240 and YM240D models should be
tightened to 372.65-411.88 N-m
(275-304 ft.-lbs.) torque.
Three Cylinder Models.
73. The crankshaft is supported in
four main bearings and end thrust is
taken by the flanged main bearing
(9-Fig. 62) located at the third (from
front) position. To remove the crank-
shaft and/or main bearings from all
models, proceed as follows:
Separate the front axle, frame and
radiator as outlined in paragraph 40,
then refer to paragraph 42 to complete
removal of engine. Refer to paragraph
45 to remove the cylinder head and to
paragraph 55 for removing the timing
gear cover. Refer to paragraph 65 to
remove the rod and piston units and to
paragraph 131 or 134 for removing the
clutch and flywheel. Pull crankshaft
gear (5-Fig. 62) from crankshaft and
remove the oil pick-up tube (30), Turn
the engine so that weight rests on front
face of cylinder block and rear end is up.
Weight of crankshaft should be vertical
against front of engine.
Unbolt and remove the rear main
bearing and seal housing (12). Jack
screw (threaded) holes are provided in
rear bearing housing to facilitate
removal. Attach hoist to rear of crank-
shaft and raise shaft slightly to remove
weight from center main bearings.
Remove set bolts from both center main
bearing housings, then carefully lift
crankshaft (10) and center main bearing
housings (8) from cylinder block.
Remove bolts from center main bearing
housings, then separate and remove
YANMAR
housings and inserts from crankshaft.
Inspect main bearings and crankshaft
using the following specifications:
YM330, YM330D
Crankshaft Main Journal-
Diameter, New-Front &
Center 69,95-69,96 mm
(2.7539-2,7543 in.)
Diameter, New-Rear 89.95-89.96 mm
(3.5413-3.5417 in.)
Wear Limit-Front & Center 69.92 mm
(2.7528 in.)
Wear Limit-Rear 89,92 mm
(3.5402 in,)
Main Bearing Diameters-
New-Front & Center 70,00-70,04 mm
(2.7559-2,7575 in,)
New-Rear 90.00-90.04 mm
(3.5433-3.5449 in.)
Wear Limit-Front & Center 70.12 mm
(2,7606 in.)
Wear Limit-Rear 90.15 mm
(3.5492 in.)
Main Journal to Bearing Clearance -
New-Front & Center 0.036-0,099 mm
(0.0014-0.0039 in.)
New-Rear 0,066-0,132 mm
(0.0026-0.0052 in.)
28
22
21
37
1
Fig. 62-Partiaiiy expioded vievn of timing gears, camshaft and cranicshaft for YM330 and YM330D models, inset is oii pressure relief valve.
1. Screw
2. Crankshaft pulley
3. Front oil seal
4. Oil deflector
5. Crankshaft gear
6. Front main bearing
7. Front indermediate main
bearing
8. Center main bearing
housings.
9. Thrust bearing
10. Crankshaft
11. Rear main bearing
12. Rear main bearing and E
housing
13. Rear oil seal
14. Flywheel
15. Oil pump
16. Oil filter
17. Hydraulic pump drive
coupling
18. Pump drive gear
19. Bearings and spacer
20. Snap ring
21. Nut
22. Governor weight
23. Camshaft gear
24. Retaining screw
25. Camshaft front bearing
26. Camshaft
27. Cam follower
28. Rocker arms
29. Oil pre.ssure sender
30. Oil pick up t
31. Nut
32. Housing
33. Relief valve
34. Spring
35. Shims
36. Retainer
37. Tachometer
Ubi
halt
drive
24
SHOP MANUAL
Paragraphs 75-80
Wear Limit-Front & Center 0.15 mm
(0.0059 in.)
Wear Limit-Rear 0.20 mm
(0.0079 in.)
The front main bearing (6) is pressed
into cylinder block and the rear main
bearing (11) is pressed into rear housing.
Be sure to align oil holes in bearings
with passages in block and housing when
pressing new bearings into position.
Rear seal (13) should be pressed into
rear bore of housing with lip toward
front (inside).
Assemble intermediate (center) main
bearing housings (8) with arrows on
casting halves aligned with "F" mark
toward FLYWHEEL end of engine. Be
sure that tangs of bearing inserts (7 and
9) correctly engage notches in housings.
Intermediate main bearing (9) with
thrust surfaces should be installed
closest to flywheel end (third main bear-
ing from front). Tighten screws holding
intermediate bearing halves together to
63.74-68.65 N-m (47-51 ft.-lbs.) torque.
Crankshaft end play should be 0.09-0.19
mm (0.0035-0.0075 in.). Lubricate all
bearings and seals with engine oil and
stand cylinder block on front face so that
crankshaft can be inserted from above.
Lower the crankshaft with intermediate
main bearings into cylinder block, align-
ing holes in intermediate housings with
bolt and lubricating holes in block. In-
stall both screws retaining intermediate
housings loosely, then tighten the re-
taining screw for rearmost (number
three) intermediate main bearing to
78.45 N-m (58 ft.-lbs.) torque. After
tightening the retaining screw for the
thrust bearing, tighten retaining screw
for the other intermediate bearing hous-
ing to 78.45 N-m (58 ft.-lbs.) torque. In-
stall the rear bearing and seal housing,
tightening the retaining screws to 37.27
N' m (27.5 ft.-lbs.) torque. Make sure
that crankshaft rotates freely and that
end play is within limits of 0.09-0.19 mm
(0.0035-0.0075 in.) after all retaining
screws are properly tightened. Flywheel
retaining screws should be tightened to
63.74-68.65 N-m (47-51 ft.-lbs.) torque.
Complete assembly by reversing
disassembly procedure.
CRANKSHAFT REAR
OIL SEAL
All Models
75. The lip type crankshaft rear oil
seal (13-Fig. 60, Fig. 61 or Fig. 62) is
contained in rear bearing and seal hous-
ing. Seal can be renewed after splitting
tractor between engine and clutch hous-
ing as outlined in paragraph 41, then
removing clutch and flywheel.
Lip of rear seal should be toward front
(inside housing). On two cylinder
models, thickness of gasket (44-Fig. 60
or Fig. 61) controls crankshaft end play.
Use grease to stick rear thrust washer
on to rear housing while assembling. Be
sure grooved side of thrust washer is
toward crankshaft thrust surface and
that lug on thrust washer engages notch
in rear housing. Crankshaft end play
should be 0.1-0.2 mm (0.0039-0.0079 in.).
Insufficient end play after assembling is
usually caused by incorrect alignment of
thrust washer.
On YM135, YM135D, YM155 and
YM155D models, tighten rear housing
retaining screws to 19.61-24.52 N*m
(14.5-18.1 ft.-lbs.) torque. On all other
models, the rear housing retaining
screws should be tightened to
29.42-39.23 N-m (22-29 ft.-lbs.) torque.
The flywheel retaining nut used on
YM195, YM195D, YM240 and YM240D
should be tightened to 372.65-411.88
N-m (275-304 ft.-lbs.) torque. The
flywheel retaining screws used on other
models, should be tightened to
63.74-68.65 N-m (47-51 ft.-lbs.) torque.
CRANKSHAFT FRONT OIL SEAL
All Models
76. The lip type crankshaft front oil
seal (3-Fig. 60, Fig. 61 or Fig. 62) can
be removed after removing crankshaft
pulley (2). Lip of seal should be toward
inside. Correct installation of seal is
much easier if front axle, radiator and
front frame is separated from front of
engine as described in paragraph 40.
FLYWHEEL
All Models
78. The flywheel is positively located
on crankshaft by a key on YM195,
YM195D, YM240 and YM240D models;
or by a dowel pin on all other models. On
all models, make sure that mating sur-
faces of flywheel and crankshaft are
clean and free of dirt, rust and burrs.
The flywheel retaining nut or screws
should be tightened to correct torque.
The flywheel retaining nut used on
YM195, YM195D, YM240 and YM240D
models should be tightened to
372.65-411.88 N-m (275-304 ft.-lbs.) tor-
que; the flywheel retaining screws used
on other models should be tightened to
63.74-68.65 N-m (47-51 ft.-lbs.) torque.
Pilot bearing is bushing type for all ex-
cept YM330 and YM330D models with
live pto which uses a ball type pilot bear-
ing. Pilot bushing inside diameter is
14.966-14.984 mm (0.5892-0.5899 in.)
for all models with bushing and shaft
out si de di amet er should be
14.935-14.953 mm (0.5880-0.5887 in.).
Clearance between shaft and pilot
bushing should be 0.3 mm (0.0118 in.).
Old bushing can be pulled from bore
with blind hole puller. Install new
bushing flush with recess in shaft or
flywheel.
Pilot bearing is ball type on YM330
and YM330D models with live pto. Ball
bearing should be renewed if any
roughness is noted.
Clutch to flywheel retaining screws
should be tightened to 22.56-29.42 N-m
(17-22 ft.-lbs.) torque.
OIL PUMP AND RELIEF VALVE
All Models
80. The rotor type oil pump is attach-
ed to the rear face of engine block and
driven by rear of camshaft on YM135,
YM135D, YM155 and YM155D models
as shown at (15-Fig. 60). On other
models, the oil pump is attached to the
front face of engine block and is gear
driven from crankshaft gear as shown at
(15-Fig. 61 or Fig. 62).
The pump can be removed from
YM135, YM135D, YM155 and YM155D
models after separating between engine
and clutch housing, then removing the
flywheel. The oil pump can be removed
from other models after removing the
timing gear housing as outlined in para-
graph 55.
Pump rotor end play in housing can be
measured with straightedge across
pump body and inserting feeler gage
between straightedge and pump rotor.
End play should be 0.06-0.10 mm
(0.0024-0.0039 in.) and should not ex-
ceed 0.3 mm (0.0051 in.). Pump outer
rotor to body bore clearance should be
0.050-0.105 mm (0.0020-0.0041 in.) with
wear limit of 0.15 mm (0.0059 in.). Pump
inner rotor tip to outer lobe clearance
should be 0.050-0.105 mm (0.0020-
0.0041 in.) with wear limit of 0.15 mm
(0.0059 in.).
On all models, oil pressure relief valve
is located in housing (32-Fig. 60, Fig.
61 or Fig. 62) for oil filter. Correct oil
pressure is 147-245 kPa (21.34-35.56 psi)
for YM135, YM135D, YM155 and
YM155D models; 245-343 kPa (35.56-
49.78 psi) for all other models. Addition
or removal of one shim (35-Fig. 62) will
change oil pressure approximately 18
kPa (2.6 psi).
DIESEL FUEL
SYSTEM
Yanmar PFR2K two plunger fuel in-
jection pump is used on all two cylinder
models and Yanmar PFR3K three
plunger fuel injection pump is used on
25

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