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Yanmar EF-494T User Manual

Yanmar EF-494T
239 pages
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EF494T TM 06/2011 edition

Table of Contents

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Yanmar EF-494T Specifications

General IconGeneral
BrandYanmar
ModelEF-494T
CategoryTractor
LanguageEnglish

Summary

SAFETY

WARNING

Critical safety warning about reading and understanding manual instructions before operation.

INTRODUCTION

To the owner of this manual

General introduction and guidance for the manual's owner.

MAINTENANCE

Instructions on what to do when the machine is in abnormal condition.

SUPPLY PERIOD FOR MAINTENANCE PARTS

Information on the duration of maintenance parts availability.

IMPROVEMENTS

Details on how parts may be changed for improvement or upgrade.

SYMBOL INDICATION

Explanation of safety symbols, signal words, and service instructions used in the manual.

PRECAUTIONS FOR THE SAFE SERVICES

General safety precautions to follow during service and repair operations.

AFTER SALES SERVICE

Information on obtaining service, troubleshooting, and spare parts availability.

GENERAL PRECAUTIONS FOR SERVICES

Essential general precautions and guidelines to follow before and during service.

SCREW TIGHTENING TORQUE TABLE

Table specifying tightening torques for various bolts and nuts according to size and material.

FUSE BOX

Identification and rating of fuses for the tractor's electrical system.

PART NAMES

Identification of external tractor parts with corresponding numerical labels.

SAFETY LABEL LOCATION

Diagram showing the location of various safety labels on the tractor.

SPECIFICATIONS

Technical specifications of the tractor model, including dimensions, engine, and transmission.

TRACTOR MASS AND TIRE SPECIFICATION

Specifications for tire size, load capacity, and axle mass limits.

PERIODICAL INSPECTION

CHECK INTERVALS

Table detailing inspection and replacement intervals for various tractor components.

OIL AND GREASE

Specifications for oils and greases recommended for the tractor's lubrication points.

OIL AND WATER VOLUME

Table listing fluid capacities and recommended oil types for engine, cooling, and transmission.

EQUIVALENT TO TF-500

List of equivalent brand names and products for TF-500 transmission fluid.

REPLACING OIL

Step-by-step instructions for checking and replacing engine and transmission oil.

REPLACING FILTER ELEMENTS

Procedures for replacing engine oil, transmission oil line, and fuel filter elements.

REPLACING COOLING WATER

Instructions for checking and replacing the tractor's cooling water.

REMOVING WATER FROM WATER SEPARATOR

Procedure for draining water from the fuel filter's water separator.

CLEANING AND REPLACING AIR CLEANER ELEMENT, CLEANING RADIATOR SCREEN

Steps for cleaning the air cleaner element and radiator screen for optimal performance.

CHECKING BATTERY

Guide on how to check the battery electrolyte level and procedures for removal/installation.

CHECKING HOSE AND PIPE

Instructions for checking hoses and pipes for leaks and recommended replacement intervals.

CHECKING ELECTRICAL WIRING

Guidelines for inspecting electrical wiring for damage and loose connections.

GREASING

Points requiring greasing and recommended intervals for daily and general maintenance.

ADJUSTING BRAKE

Procedure for checking and adjusting the tractor's brake pedal play and effectiveness.

ADJUSTING CLUTCH

Steps for checking and adjusting the clutch pedal free play.

ADJUSTING STEERING WHEEL

Guidelines for checking and adjusting the steering wheel free play.

ADJUSTING FAN BELT

Procedure for checking fan belt tension and adjusting or replacing it.

ADJUSTING TOW-IN

Method for measuring and adjusting front wheel toe-in for proper steering.

REPLACING FUSE

Instructions on how to check and replace blown fuses in the fuse box.

CHECKING TIRES

Guidance on checking tire air pressure, cracks, and damage.

COLOR OF EXHAUST GAS

Interpretation of exhaust gas colors to diagnose engine conditions.

DISASSEMBLY OF COMPONENTS

REMOVING THE ENGINE BONNET COVER

Detailed steps for removing and installing the engine bonnet and side covers.

REMOVING THE FENDER

Procedures for removing the fuel tank cover and the fender assembly.

REMOVING THE STEP

Steps for removing the tractor's side steps and associated covers.

REMOVING THE SEAT STAY

Instructions for removing the seat stay, which involves draining the fuel tank.

CLUTCH HOUSING

Step-by-step guide for separating the clutch housing from the tractor.

TRANSMISSION

Detailed procedures for separating the hydraulic cylinder case and the clutch housing from the transmission.

REAR AXLE AND BRAKE

Steps for disassembling the rear axle housing, including draining oil and removing wheels.

FRONT AXLE UNIT

Procedures for disassembling and reassembling the front axle unit, including the drive pinion.

TRANSMISSION

POWER TRANSMITTING DIAGRAM

Schematic illustration showing the power flow through the tractor's transmission system.

TRANSMISSION SYSTEM CROSS-SECTION

Detailed cross-section view of the transmission system, illustrating internal components and shafts.

TRANSMISSION SYSTEM

Explanation of the main shift, reverse shift, range shift, front drive, and PTO shift modules.

Main shift module

Description of the constant-mesh main shift module and gear engagement.

Reverse shift module

Explanation of the constant-mesh reverse shift module and gear engagement.

Range shift module

Details on the constant-mesh range shift module and its gear engagement.

Front drive

Explanation of the front drive engagement mechanism and power transfer.

PTO shift module

Description of the constant-mesh PTO shift module and power output engagement.

TRANSMISSION (CLUTCH HOUSING CASE SIDE)

Identification of gears within the clutch housing and reverse modules.

Disassembly

Step-by-step instructions for disassembling the transmission components from the clutch housing side.

Main shift section

Detailed view and explanation of the main shift section and its detent mechanism.

TRANSMISSION (TRANSMISSION HOUSING CASE SIDE)

Identification of components on the right, left, and center plate sides of the transmission housing.

Disassembly

Procedures for disassembling the PTO module and related components.

PTO module

Instructions for removing the PTO module from the transmission housing.

REAR AXLE AND BRAKE

STRUCTURE AND FUNCTIONS

Overview of the rear axle's design for power transmission and its components.

Structure drawing

Diagram illustrating the structure of the rear axle, including differential and final reduction gears.

Differential system

Explanation of the differential gear mechanism, its function, and differential lock operation.

Final drive system

Description of the planetary final drive system, providing high torque and reduction.

Brake

Explanation of the wet-type disc brake system, including its operation and parking brake function.

DISASSEMBLY AND ASSEMBLY

Steps for disassembling and reassembling the differential system and related parts.

Differential system

Procedures for removing the hydraulic cylinder case and differential lock fork.

Rear axle oil seal

Instructions for removing and assembling the rear axle oil seal and bearing.

Planetary gears and axle shaft

Steps for removing and assembling the planetary gears and axle shaft.

FRONT AXLE

STRUCTURE AND FUNCTIONS

Overview of the four-wheel drive front axle system and power transfer.

Structure drawing

Diagram showing the layout of the four-wheel drive front axle components.

CROSS-SECTION VIEW

Detailed cross-section view of the front axle, illustrating internal mechanisms.

FRONT WHEEL ALIGNMENT

Explanation of front wheel alignment factors and adjustment of toe-in.

DISASSEMBLING THE FRONT BEARING CASE

Procedure for removing the front axle bearing case, including shims.

DISASSEMBLING THE FRONT GEAR BOX

Steps for supporting and removing the front gear box and knuckle arm.

DISASSEMBLING AND REASSEMBLING THE FRONT DIFFERENTIAL SECTION

Procedures for disassembling and reassembling the front differential section.

Disassembly

Steps for draining oil, removing wheels, tie rod, and front gear case.

Assembly

Procedures for assembling the front axle drive pinion and bearings, including preload adjustment.

POWER STEERING

STRUCTURE AND FUNCTIONS

Overview of the power steering system's main components and structure.

Structure drawing

Diagram illustrating the power steering cylinder, valve, and hydraulic pump.

Hydraulic circuit

Schematic of the power steering hydraulic circuit, showing oil flow and relief valve operation.

Power steering valve functions

Explanation of the power steering valve's operation in neutral, during rotation, and manual rotation.

Hydraulic pump

Exploded view and specifications of the front hydraulic pump.

Power steering

Exploded view of the power steering cylinder assembly components.

POWER STEERING VALVE

Procedures for removing the power steering valve assembly.

Removing power steering valve assembly

Detailed steps for removing the dashboard covers and the steering valve.

Power steering relief pressure

Method for measuring and adjusting the power steering relief pressure.

Disassembly

Exploded view and parts list for disassembling the power steering valve.

HYDRAULIC LIFT UNIT

STRUCTURE AND FUNCTIONS

Overview of the hydraulic lift unit's structure and components.

Hydraulic line

Diagram showing the hydraulic lines connecting the pump, filter, and cylinder.

Hydraulic cylinder case

Exploded view of the hydraulic cylinder case and its associated parts.

Control valve

Explanation of the control valve's functions and operation.

Relief valve

Description of the relief valve's function and pressure setting adjustment.

Safety valve

Explanation of the safety valve's function and pressure setting adjustment.

Stop valve

Description of the stop valve's use in controlling motion and lowering speed.

Hydraulic pump, exploded view

Exploded view of the hydraulic pump and its parts.

Position feedback link

Explanation of the position feedback link's role in controlling the lift arm movement.

Oil flow

Diagrams illustrating hydraulic oil flow in neutral, lift, and lowering operations.

Oil flow at Neutral

Diagram showing hydraulic oil flow when the control valve is in the neutral position.

ASSEMBLY AND CHECK

Procedures for assembling and checking the control valve.

Assembling/disassembling the control valve

Steps for removing and assembling the control valve from the hydraulic cylinder case.

Control valve, exploded view

Exploded view of the control valve components and disassembly precautions.

Main relief pressure

Procedure for measuring and adjusting the main relief pressure of the hydraulic system.

Adjusting the position feedback rod

Steps for adjusting the position feedback rod to set lift arm free play.

HYDRAULIC POWER TAKE OFF

Information on obtaining hydraulic pressure for single and double action devices.

For single action; pump trailer etc.

Operation procedure for single-acting hydraulic cylinders.

For double action; front blade etc.

Operation procedure for double-acting hydraulic cylinders.

Hydraulic pressure flow

Diagrams illustrating hydraulic pressure flow for 3-point hitch and double action PTO.

ELECTRIC EQUIPMENT

ENGINE START CIRCUIT

Location and operation of components related to the engine start circuit.

Location and operation of components

Identification and function of electrical components for engine starting.

Circuit diagram (Engine start)

Electrical schematic diagram for the engine starting system.

Checkpoints of electrical equipment

Tests and checks for electrical equipment, including starter motor and fuel shut off solenoid.

Fuel shut off solenoid

Measurements and checks for the fuel shut off solenoid and its coupler.

Fuel feed pump

Individual component check for the fuel feed pump.

Solenoid relay

Single item check for the solenoid relay.

Timer

Information about the timer component.

Key switch

Terminal connection table and single item check for the key switch.

Combination switch

Single item check for the combination switch functions.

Turn signal lamp right and left (20 W)

Single item check for turn signal lamps.

CHARGING CIRCUIT

Location and operation of components for the tractor's charging circuit.

Location and operation of components

Identification of battery, fuses, alternator, and instrument panel.

Circuit diagram (Charging)

Electrical schematic diagram for the charging system.

Checkpoints of electrical equipment

Tests and checks for alternator, instrument panel, and key switch.

Alternator

Information and checks related to the alternator.

Instrument panel

Description of instrument panel functions and key switch operation.

Key switch

Reference to key switch details in the engine start circuit section.

ALARM CIRCUIT

Location and operation of components related to the alarm circuit.

Location and operation of components

Identification of battery, fuses, sensors, and switches for the alarm system.

Circuit diagram (Alarm)

Electrical schematic diagram for the alarm circuit.

Checkpoints of electrical equipment

Tests and checks for water temperature sensor and oil pressure switch.

Water temperature sensor

Information and checks for the water temperature sensor.

Oil pressure switch

Single item check for the oil pressure switch.

Instrument panel

Description of instrument panel gauges and indicators.

Key switch

Reference to key switch details in the engine start circuit section.

Alternator 40 A

Reference to alternator details in the charging circuit section.

Fuel gauge sensor

Single item check for the fuel gauge sensor.

SAFETY CIRCUIT

Location and operation of components for the tractor's safety circuit.

Location and operation of components

Identification of head lamps, horn, battery, fuses, relays, and switches.

Circuit diagram (Safety)

Electrical schematic diagram for the safety circuit.

Checkpoints of electrical equipment

Tests and checks for head lamps, horn, head lamp relay, and flasher relay.

Head lamp (12V45W/45W)

Single item check for the tractor's head lamps.

Horn

Single item check for the tractor's horn.

Head lamp relay

Single item check for the head lamp relay.

Flasher relay

Information on the flasher relay.

Key switch

Terminal connection table and single item check for the key switch.

Combination switch

Single item check for the combination switch.

Turn signal lamp right and left (20 W)

Single item check for turn signal lamps.

APPENDIXES

HYDRAULIC CIRCUIT DIAGRAM

Overall hydraulic circuit diagram of the tractor's systems.

ELECTRICAL CIRCUIT DIAGRAM

Overall wiring harness diagram for the tractor's electrical system.

WIRING HARNESS

Diagram showing the layout and connections of the tractor's wiring harness.

LOCATION OF ELECTRICAL PARTS

Diagram showing the physical locations of various electrical components on the tractor.

ELECTRICAL WIRING DIAGRAM

Detailed wiring diagram illustrating the electrical connections and circuits.

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